2003 Mitsubishi Lancer Workshop Manual

Spark Plug - Fouling
Spark Plug: Customer Interest Spark Plug - Fouling

NO.: TSB-95-16-003
DATE: November, 1995
MODEL: All Models
SUBJECT: SPARK PLUG FOULING
BACKGROUND INFORMATION
Short, frequent engine starts during transportation of new vehicles for delivery to dealers can cause
spark plug fouling. Customers who drive short distances in cold weather may also experience
spark plug fouling. If a vehicle is hard to start or experiences rough idle or misfire, the spark plugs
may be wet or have some accumulated carbon deposits.
Cleaning the plugs should correct the problem. Spark plug replacement should not be necessary.
VEHICLES AFFECTED
All models
PROCEDURE
1. Start the engine and warm to normal operating temperature.
2. Clean the spark plugs as follows:
CAUTION:
Do not exceed the driving or engine rpm speeds listed below.
a. Drive the vehicle at 25-40 mph at 4,000 to 4,500 rpm for five minutes. This will bring the spark
plug temperature up to a point that will burn off the carbon deposits.
b. If the above driving method does not correct the problem, remove the spark plugs and use an
appropriate spark plug cleaner to remove carbon deposits.
WARRANTY INFORMATION
Use standard warranty procedures.

Page 498
Barometric Pressure Sensor: Testing and Inspection
TROUBLESHOOTING HINTS
Hint 1: If there is a malfunction of the barometric pressure sensor, driveablity of the vehicle will
become worse, particularly at high altitudes. Hint 2: If, during high-speed driving, there is a
noticeable sharp drop of the displayed pressure of the barometric-pressure sensor, check for
clogging of the air cleaner.
INSPECTION
Using Scan Tool

Component Locations
Relay Box: Component Locations

Page 3042
Grounding Markings
How to Read Circuit Diagrams

Page 5113
Starter Relay: Testing and Inspection
Starter Relay
Starter Relay - Chart
1. Remove the starter relay. 2. Connect the battery to terminal(1) and check the continuity between
the terminals with terminal(2) grounded.
A/T - Park/Neutral Position Switch Adjustment
Transmission Position Switch/Sensor: Technical Service Bulletins A/T - Park/Neutral Position

Switch Adjustment
NO.: TSB-98-23-012 DATE: August, 1998 MODEL See below
SUBJECT: PARK/NEUTRAL POSITION SWITCH ADJUSTMENT - SERVICE MANUAL REVISION
[TSB Revision TSB-98-23-012]
PURPOSE This bulletin corrects the park/neutral position switch adjustment procedures in the
affected service manual pages. The electronically-controlled V4AW3 A/T used since the 1994
model year requires a slightly different park/neutral position switch adjustment procedure from the
V4AW2 A/T.
To determine which A/T model is installed, check on the Vehicle Information Code Plate located in
the engine compartment on the cowl top outer panel.
Write the TSB revision number of this bulletin in the "TSB Revision" box at the bottom of the
affected service manual pages.
AFFECTED VEHICLES 1994-98 Montero models equipped with V4AW3 automatic transmission
AFFECTED SERVICE MANUAL PAGES 1992-95 Montero, Volume 1, page 23-48 1996 Montero,
Volume 1, page 23A-44 1997 Montero, Volume 1, page 23A-45 1998 Montero, Volume 1, page
23A-45
Page 6533
Air Bag(s) Arming and Disarming: Technician Safety Information

1. In order to avoid injury to yourself or others from accidental deployment of the air bag during
servicing, read and carefully follow all the
precautions and procedures.
2. Do not use any electrical test equipment on or near SRS components.
Never use an analog ohmmeter.
3. Never Attempt to Repair the Following Components
- Front Impact Sensors
- SRS Air Bag Control Unit (SRS-ECU)
- Clock Spring
- Air Bag Module
If any of these components are diagnosed as faulty, they should only be replaced, in accordance
with the COMPONENT SERVICE procedures in this manual.
Service Precautions
4. Do not attempt to repair the wiring harness connectors of the SRS. If any of the connectors are
diagnosed as faulty, replace the wiring harness. If
the wires are diagnosed as faulty, replace or repair the wiring harness according to the following
table.
SRS-ECU Connector
Page 796
Page 6989
License Plate Lamp: Testing and Inspection
1. All lights do not illuminate.
a. Headlights illuminate.
- Check dedicated fuse No. 5.
- Check the tail light relay. See: Relays and Modules - Lighting and Horns/Tail Lamp Relay/Testing
and Inspection
- Check the lighting switch. See: Testing and Inspection
b. The headlights also do not illuminate or the charging warning light does not turn off.
- Check fusible link No. 13.
2. Either light does not illuminate.
- Check the bulb.
- Check the ground circuit.

Page 2885
STEP 2. Check for an open-circuit, or a short-circuit to ground, between the engine control module
and the heated oxygen sensor. -
Heated oxygen sensor connector: Disconnected
- Engine control module connector: Disconnected OK: GO TO STEP 3 NG: Repair the harness.
(A4 - 79, B4 - 76, C4 - 73, D4 - 75)
(A3 - 42, 63 - 34, C3 - 43, D3 - 35)
STEP 4. Check for continuity of the ground circuit. -
Heated oxygen sensor connector: Disconnected OK: STOP NG: Repair the harness. (A2, 62, C2,
D2 - 92)
HEATED OXYGEN SENSOR CHECK
(1) Disconnect the connector to the heated oxygen sensor, then use the special tool (test harness)
to make connections with the connection on the
heated oxygen sensor side.
(2) Check that there is continuity between terminal (1) (red clip of the special tool) and terminal (3)
(blue clip) of the heated oxygen sensor
connector [approx. 12 Ohm at a temperature of 20°C (68°F)].
(3) It there is no continuity, replace the heated oxygen sensor.

Page 5335
e. Rotor installation (6).
Install the rotor to the pulley assembly so that the rotor's punch mark is at the pump cover side.
f. Snap ring installation (5). After installation of the snap ring, lift the rotor and check that the snap
ring has entered the countersunk part.
g. Cam ring installation (4).
Install the cam ring with the punch mark facing the side plate.
h. Vane installation (3).
Install the vanes on the rotor, paying close attention to the installation direction.
Diagram Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Connector and Ground Indicators
Connector/Grounding Indications

Switch Adjustment
V4AW2 A/T.
23A-45
Page 5954
How To Read Configuration Diagrams
The Wiring harness diagram clearly show the connector locations and harness routings at each site
on actual vehicles.
Wire Color Codes
Valve Lash Adjuster Noise - Troubleshooting Procedures
Lifter / Lash Adjuster: All Technical Service Bulletins Valve Lash Adjuster Noise - Troubleshooting
Procedures
NO.: TSB-97-11-002 DATE: February, 1997 MODEL: See Below
SUBJECT: NEW VALVE LASH ADJUSTER NOISE CHECKING AND TROUBLESHOOTING

PROCEDURES
PURPOSE This bulletin contains new information for checking and troubleshooting suspected
valve lash adjuster noise for all listed affected vehicles. This information is in addition to the
information already in Group 11 of each vehicle's service manuals. Be sure to use the information
in this bulletin along with the service manual when diagnosing suspected valve lash adjuster noise.
AFFECTED MODELS 1991-97 3000GT 1992-96 Diamante 1990-97 Eclipse 1992-96 Expo/Expo
LRV 1989-97 Galant 1990-92 Mirage 1989-97 Montero 1989
Starion
1990-96 Truck 1989-90 Van/Wagon
SERVICE MANUAL REVISION
The engine troubleshooting chart in the service manuals for all affected models requires one
revision concerning the symptom of "Noisy valves". Make the change to all affected manuals as
shown.
PROCEDURES
Lash Adjuster Noise Check
If an abnormal noise (chattering or clicking noise), suspected to be a malfunctioning lash adjuster,

is produced immediately after starting the engine and does not go away, perform the following
checks:
NOTE: (1)
An abnormal noise caused by a malfunctioning valve lash adjuster is produced immediately after
starting the engine and changes with the engine speed, no matter what the engine load.
Therefore, if abnormal noise is not apparent just after starting the engine, if it does not change with
engine speed, or if it changes with engine load, the noise is not caused by a malfunctioning lash
adjuster.
Engine - Fouled Spark Plugs Causing Misfire
Spark Plug: All Technical Service Bulletins Engine - Fouled Spark Plugs Causing Misfire
No: TT-124-13-001 DATE: March, 2006 MODEL: See Below
SUBJECT: FOULED SPARK PLUGS
Fouled Spark Plugs - All models. If a stored vehicle is only driven short distances on the dealership
lot, the spark plugs may become fouled. This could cause a misfire condition. To prevent this,
always allow the engine to reach normal operating temperature before turning off the ignition.
Page 2427
on actual vehicles.
Wire Color Codes
Page 6838
Brake Lamp: Electrical Diagrams
Stop Light (Part 1 Of 2)

Locations
Alternator Relay: Locations
Relay Location Overviews

Page 5333
Power Steering Pump: Service and Repair Overhaul
DISASSEMBLY
Follow disassembly steps outlined in illustration.
REASSEMBLY
Assembly in reverse order as Disassembly.
NOTE: Assembly service points as follows:

Page 7015
on actual vehicles.
Wire Color Codes
Page 3388
Connector And Terminal Marking

Page 2867
Oxygen Sensor: Locations Right Bank Heated Oxygen Sensor (Front & Rear)
Sensor Location Overviews

Page 4759
CONTROL UNIT VIEW
ABS Control Unit H
Testing and Inspection
Suspension Control Module: Testing and Inspection

Page 1533
Grounding Markings

Page 9
1992-95 Montero Service Manual, Volume 2, Page 54-144 Add the new inspection procedures to
the top of page 54-144 in place of the procedures deleted previously.
Fuel Tank Pressure Sensor: Diagram Information and Instructions
Page 3008
Camshaft Position Sensor: Diagram Information and Instructions
Page 4057
1992-95 Montero, Volume 1, page 23-48
Page 4741
Acceleration/Deceleration Sensor: Locations

Page 3306
Checking the operation
(1) Remove the throttle body. (2) Remove the stepper motor.
(3) Connect the special tool (test harness) to the idle air control motor connector. (4) Connect the
positive terminal of a power source (approx 6 V) to the white clip or the green clip.
(5) While holding the idle air control motor as shown in the illustration, connect the negative power
source terminal to each clip in the sequence
described below, and check whether or not there is vibration (a feeling of very slight shaking of the
stepper motor) as a result of activation of the stepper motor. 1) Connect the negative power source
terminal to the red and black clips. 2) Connect the negative power source terminal to the blue and
black clips. 3) Connect the negative power source terminal to the blue and yellow clips. 4) Connect
the negative power source terminal to the red and yellow clips. 5) Connect the negative power
source terminal to the red and black clips. 6) Repeat the test in the reverse (5-1) sequence.
(6) If vibration is felt as a result of this test, the stepper motor can be considered to be normal.
Page 602
How To Read Circuit Diagrams (Part 2 Of 2)

The circuit of each system from the fuse (or fusible link) to ground is shown. The power supply is
shown at the top and the ground at the bottom to facilitate understanding of how the current flows.
How to Read Connector/Harness Diagrams

Page 6619
Grounding Markings

Page 1301
(2) If a lash adjuster malfunctions, the abnormal noise is rarely eliminated by continuing engine
warm-up at idle speed. However, the noise may disappear only when lash adjuster seizure is
caused by oil sludge in an engine which has not been maintained properly.
1. Start the engine.
2. Check to see if the abnormal noise is produced immediately after starting the engine and that the
noise changes with engine speed.
If this noise is not present just after starting the engine or if it does not change with engine speed, a
malfunctioning lash adjuster is not the cause of the noise. Investigate for other causes. In this case
the lash adjuster is in good condition and the noise is probably caused by other parts in the engine.
3. With the engine idling, change the engine load (shift from N to D, for example). to make sure
there is no change in the level of the abnormal noise. If there is a change, suspect a tapping noise
caused by a worn crankshaft or connecting rod bearing. In this case, the lash adjuster is in good
condition.
4. After the engine is warmed-up, run at idle to check for the abnormal noise.
If the noise is reduced or disappears, make the following checks to see if the noise is caused by
the suspected seizure of the lash adjuster. If there is no change in the noise, proceed to Step 5.
a. Cool the engine sufficiently.
b. Turn the crankshaft two turns.
c. Perform the following simple valve lash adjuster check. (The simple lash adjuster checking
procedure is shown in more detail at the end of this bulletin.)
^ With the rocker cover removed, push down on each rocker arm. Replace the lash adjuster on any
valve where you can push the rocker arm down easily.
^ If the rocker arm cannot be pushed down easily, that lash adjuster is good. Check for other
possible causes for the abnormal noise.
NOTE
The lash adjuster can also be checked correctly by using the leak down test found in the particular
service manual (Group 11 - Rocker Arm and Camshaft) for the vehicle being diagnosed.
CAUTION
Be sure to bleed the air from a new valve lash adjuster before installing it. For lash adjuster air
bleeding procedures, refer to the air bleeding procedures further along in this bulletin or the proper
service manual, (Group 11 - Rocker Arm and Camshaft).
5. Run the engine to bleed the lash adjuster system.
6. If the abnormal noise is not eliminated after bleeding the air, do the following checks:
a. Perform the simple lash adjuster check from step 4.c.
^ If only one lash adjuster is bad after doing the simple lash adjuster check (pushing down on the
rocker arm), replace that adjuster.
^ If two or more lash adjusters are found abnormal (the rocker arm pushes down easily), then
suspect clogged oil passage(s) in the cylinder head. If this is the case, check for clogged oil
passages and repair as necessary. If the oil passages are not clogged, replace the lash adjuster.
Page 2409
Wire Color Codes
Wire colors are identified by the following color codes. If a cable has two colors, the first of the two
color code characters indicates the basic color (color of the cable coating) and the second indicates
the marking color.
Wire Color Codes - Example
Example of Wire Color Code

Rear Differential Lock Detection Switch
Switch: Testing and Inspection Rear Differential Lock Detection Switch
Inspection
1. Raise up the vehicle. 2. Remove the air pipe and air hose connections. 3. Connect a pressure
gauge and air regulator, for adjusting the compressed air pressure, to the air hose. 4. Adjust the
compressed air pressure with the air regulator until the pressure gage shows a pressure of
approximately 25 kPa (4 psi.).
CAUTION: Do not apply a higher pressure.
5. Hold the wheel on one side of the vehicle stationary, and slowly turn the wheel on the other side.
6. Check for continuity in the rear differential lock detection switch.
When air is supplied: Continuity. When air is released: No continuity.
7. If the detection switch is defective, first remove the differential carrier, then remove the detection
switch.
Continuity Check
1. Connect an ohmmeter to the detection switch connector. 2. The rear differential lock detection
switch is in good condition when the rod of the detection switch is pulled, there should be
continuity, and when
it is returned to its normal position, no continuity.
NOTE: Remove the differential carrier in order to replace the rear differential lock detection switch.
Page 4444

Page 4686

Page 1536
on actual vehicles.
Wire Color Codes
Page 89
Relay Location Views A - J
RELAY VIEW
Horn Relay C
Page 2670
Power Steering Pressure Switch: Description and Operation
OPERATION
- The power steering pressure switch converts presence/absence of power steering load into
low/high voltage and inputs it to the engine control module, which then controls the idle air control
motor based on this signal.
- The battery positive voltage in the engine control module is applied through a resistor to the
power steering pressure switch. Steering operation causes the power steering fluid pressure to
increase, turning the switch on. As a result, continuity is produced between the battery positive
terminal and the ground. This causes the power steering fluid pressure terminal voltage to go from
high to low.
Page 187
Wave pattern observation points
Point: Condition of wave pattern build-up and maximum voltage (Refer to abnormal wave pattern
examples 1 and 2.)
Examples of abnormal wave patterns
Example 1 Wave pattern during engine cranking Cause of problem
Open circuit in ignition primary circuit
Wave pattern characteristics
Top-right part of the build-up section cannot be seen, and voltage value is approximately 2 V too
low.
- Example 2 Wave pattern during engine cranking Cause of problem
Malfunction of ignition power transistor
Power voltage results when the ignition power transistor is on.

Page 3106
Leak Detection Solenoid: Testing and Inspection Component Inspection
1. Connect a hand vacuum pump to nipple (A) of the solenoid (refer to the illustration at left).
2. Check airtightness by applying a vacuum with voltage applied directly from the battery to the
evaporative emission ventilation solenoid.
3. Measure the resistance between the terminals of the solenoid valve.
Standard value: 17 - 21 Ohms [at 20°C (68°F)]

Page 2750
HARNESS INSPECTION
STEP 1. Check for continuity in the ground circuit. -
Volume air flow sensor connector: Disconnected OK: GO TO STEP 2 NG: Repair the harnesses.
(A5 - 92)
STEP 2. Check for an open or short-circuit between the barometric pressure sensor and the engine
control module. -
Volume air flow sensor connector: Disconnected
- Engine control module connector: Disconnected OK: GO TO STEP 3 NG: Repair the harnesses.
(A1 - 81, A2 - 85)
STEP 3. Measure the power supply voltage of the barometric pressure sensor. -
- Ignition switch: ON
- Engine control module connector: Connected Voltage (V): 4.8 - 5.2 OK: STOP NG: Replace the
engine control module.
Page 5878
4. Wrap two 3-foot long heavy wires around the air bag module mounting studs. Use nuts to secure
the wires.
5. Connect the adapter harness to the air bag module. Then place the air bag module in the center
of an old used mounted tire.
6. Use the heavy wires to secure the air bag module to the tire.
7. Place the tire flat on the ground with the air bag module facing up. To prevent damaging the
adapter harness, be sure the harness has about one foot of slack when placed under the tire.
8. Stack three unmounted used tires on top of the air bag module.
! WARNING
To avoid personal injury, do not deploy the air bag module when anyone is near the deployment
area.
9. At an upwind location as far away from the air bag module as possible, separate the two
short-circuited wires.
10. To deploy the air bag, connect the two wires to the two battery terminals.
Page 6687
Grounding Markings

Page 2283
Grounding Markings

Page 456
Headlamp Dimmer Switch: Testing and Inspection
Lighting Switch Table
Passing Switch
Passing Switch
NOTE: P1 represents the passing operation when the dimmer switch is in the LOW BEAM position,
and P2 represents the operation when it is in the HIGH BEAM position.
Symptom Related Diagnostic Procedures
Page 3698
on actual vehicles.
Wire Color Codes
Specifications
Fuel Injector: Specifications INJECTOR
INJECTOR
13-16 Ohms @ 20 Deg. C (68 Deg. F)

Page 4160
Page 2975
Spark Plug: All Technical Service Bulletins Spark Plug - Fouling
NO.: TSB-95-16-003
MODEL: All Models
VEHICLES AFFECTED
All models
PROCEDURE
CAUTION:

Page 3732
1996 Montero, Volume 1, page 23A-19. Refer to page 10 of TSB-97-23-001.

Page 1008
Spark Plug: Specifications GAP
GAP
Spark plug gap mm. 1.0-1.1 mm.
Spark plug gap in. 0.039-0.043 in.
Spark plug torque 15-21 ft. lb.

Service and Repair
Evaporator Case: Service and Repair
REMOVAL AND INSTALLATION
INSTALLATION SERVICE POINT
>A< EVAPORATOR INSTALLATION
When replacing the evaporator with new one, refill the evaporator with a specified amount of
compressor oil and install it to the vehicle. Compressor oil: ND-OIL 8 Quantity: 40 cubic cm (1.4
fl.oz.)
INSPECTION
- Check for damage to the evaporator fin part.
- Check for damage or collapse of the drain hose.
- Check for peeling or cracking of the insulator.

Lighting/Brakes - Brake Light Switch Service Precautions
Brake Light Switch: Technical Service Bulletins Lighting/Brakes - Brake Light Switch Service
Precautions
No: TSB-08-35-001 DATE: January, 2008 MODEL: All Models exc. Raider
SUBJECT: CAUTIONARY INSTRUCTIONS FOR HANDLING STOP LIGHT SWITCHES -

PURPOSE
Cautionary instructions for handling the stop light switch are being added to the applicable Service
Manuals of affected vehicles. This TSB contains the added information.
AFFECTED VEHICLES
All models except Raider.

Page 6609
Wire Color Codes
the marking color.

Page 5461
Ball Joint: Tools and Equipment
Specified sealant:
Upper ball joint dust cover to upper ball joint groove: 3M ATD Part No. 8661 or equivalent.
Page 6197
SPECIFIC 1994-1998 MONTERO REAR CARGO MAT MODIFICATION
1. REAR CARGO MAT MODIFICATION CLAIM

Page 2663

Page 6645
on actual vehicles.
Wire Color Codes
Front Output Shaft
Key Reminder Switch: Diagram Information and Instructions
Page 791
Grounding Markings

Page 1050
Hose/Line HVAC: Service and Repair
>A< SUCTION HOSE/RECEIVER INSTALLATION
When replacing the suction hose or the receiver with new ones, refill them with a specified amount
of compressor oil and then install each of them. Compressor oil: ND-OIL 8 Quantity:
Suction hose: 10 cubic cm (0.3 fl.oz.) Receiver: 10 cubic cm (0.3 fl.oz.)

Crankshaft Position Sensor: Diagram Information and Instructions
Page 624

Page 3461
Page 2974
Wire Color Codes
the marking color.

Page 800
Voltage (V): 4.8 - 5.2 OK: STOP NG: Replace the engine control module.
Page 6472

Page 5842
Air Bag(s) Arming and Disarming: Vehicle Damage Warnings
If the SRS components are to be removed or replaced as a result of maintenance, troubleshooting,
etc., follow each procedure.
CAUTION:
1. SRS components should not be subjected to heat over 93°C (200°F) so remove the front impact
sensors, SRS diagnosis unit, air bag modules and
clock spring before drying or baking the vehicle after painting. Recheck SRS system operability
after re-installing them.
2. If the SRS components are removed for the purpose of inspection, sheet metal repair, painting,
etc., they should be stored in a clean, dry place
until they are reinstalled.

Page 5012
Page 4262

Page 6743
Wire Color Codes
the marking color.

Page 2501
Cranking Signal: Description and Operation
NOTE: Manual Transmission Only.
OPERATION
- The ignition switch-ST inputs HIGH signals to the engine control module during engine cranking.
The engine control module, based on those signals, regulates fuel injection during starting, etc.
- When the ignition switch is turned to the START position, the battery positive voltage during
engine cranking is applied to the engine control module by way of the ignition switch, and the
engine control module thus detects the fact that the engine is cranking.
Specifications
Oil Pressure Gauge: Specifications
Oil pressure gage resistance ...............................................................................................................
......................................................... Approx. 50 Ohm
Page 3487
Page 422
Wire Color Codes
the marking color.

Page 1983
Grounding Markings

Page 2411
Air Flow Meter/Sensor: Description and Operation
OPERATION
- The volume air flow sensor is incorporated within the air cleaner, it functions to convert the
amount of engine air intake to pulse signals of a frequency proportional to the amount of engine air
intake, and to input those signals to the engine control module. The engine control module then,
based upon those signals, calculates the amount of fuel injection, etc.
- The power for the volume air flow sensor is supplied from the MFI relay to the volume air flow
sensor, and is grounded at the engine control module. The volume air flow sensor, by intermitting
the flow of the 5 V voltage applied from the engine control module, produces pulse signals.
Page 1512
1996 Montero Service Manual, Volume 1, Page 11B-59 Correct the upper oil pan installation
procedures as shown.
Page 3337
Fuel Pump Relay: Testing and Inspection
FUEL PUMP RELAY CHECK
(1) Check for continuity between the fuel pump relay terminals. (2) If there is a problem, replace the
fuel pump relay.
Page 6089
on actual vehicles.
Wire Color Codes
Page 28
CONTROL UNIT VIEW
Door Lock Control Unit F
Page 3372


Page 196
Air Bag Control Module: Service and Repair
CAUTION:
1. Never attempt to disassemble or repair the SRS-ECU. If faulty, replace it. 2. Do not drop or
subject the SRS-ECU to impact or vibration. If dents, cracking, deformation, or rust are discovered
on the SRS-ECU, replace it
with a new SRS-ECU. Discard the old one.
3. After deployment of the air bags, replace the SRS-ECU with a new one. 4. Never use an
ohmmeter on or near the SRS-ECU, and use only the special test equipment described.
Pre-removal Operation
Turn the ignition key to the "LOCK" position.
SRS Air Bag Control Unit (SRS-ECU
Removal Steps
- Post-installation inspection
1. Negative (-) battery cable connection 2. Rear console assembly 3. Front console assembly 4.
SRS air bag control unit assembly 5. SRS air bag control unit (SRS-ECU) 6. Bracket
Step 1: Negative (-) Battery Cable Disconnection
Disconnect the negative battery cable from the battery and tape the terminal.
CAUTION: Wait at least 60 seconds after disconnecting the battery cable before doing any further
work.
Page 2820
Grounding Markings

Page 3719
Grounding Markings

Locations
Power Window Relay: Locations

Brake Light Switch: Diagram Information and Instructions
Page 2803
Crankshaft Position Sensor: Description and Operation
OPERATION
- The crankshaft position sensor functions to detect the crank angle (position) of each cylinder, and
to convert those data to pulse signals, which are then input to the engine control module. The
engine control module, based upon those signals, calculates the engine rpm, and also regulates
the fuel injection timing and the ignition timing.
- The power for the crankshaft position sensor is supplied from the MFI relay and is grounded to
the vehicle body. The crankshaft position sensor, by intermitting the flow (to ground) of the 5 V
voltage applied from the engine control module, produces pulse signals.
Locations
Air Flow Meter/Sensor: Locations

Sensor Location Views A - H
SENSOR VIEW
Volume Air Flow Sensor A
(With Built-in Intake Air Temperature Sensor and Barometric Pressure Sensor)
Page 5862
1992-96 3000GT service manual, volume 1, page 52B-25 Add the new SRS troubleshooting
information to the indicated service manual page as shown.
Page 4325
Using the illustration, cut individual pieces from the two rolls of sound reduction sheets into the
sizes required then apply them to the indicated areas on the floorpan under the interior carpet. You
can use a heat gun on the sound reduction sheets to soften the material so it conforms more easily
to the contours of the body sheet metal.
RUBBER BODY MOUNT INSTALLATION (1995-97 MODELS)
Using the illustration, replace the 6 indicated body mounts with the new mounts provided in the kit.
NOTE:
Body Mount Installation Tip.
For easier body mount replacement, loosen all 6 body mounts on one side of the vehicle. Lift the
body of the vehicle about 1 inch using jack stands and a long board (preferably a 4 x 4) placed on
the body sill. You can then remove and replace the three body mounts as shown. Make sure you
tighten all 6 body mounts securely, then repeat for the other side of the vehicle.
** TRAILING ARM DAMPER AND REAR SPRING SEAT REPLACEMENT (All 1995-99 Models)
Page 5117
CAUTION: Be careful not to get your fingers caught when pulling out the pinion.
Page 513
Camshaft Position Sensor: Description and Operation
OPERATION
- The camshaft position sensor senses the top dead center on compression stroke, converts it into
a pulse signal and inputs it to the engine control module, which then computes the fuel injection
sequence, etc. based on the input signal.
- Power to the camshaft position sensor is supplied from the multiport fuel injection relay and is
grounded to the body. The camshaft position sensor generates a pulse signal as it repeatedly
connects to and disconnects from the 5 V voltage supplied from the engine control module and
ground.
Page 307
Wheel Speed Sensor: Locations

Page 3404
1992-96 Engine Overhaul Manual, page 11E-53
Page 1185

Page 1395
NOTE: The side rails and spacer may be installed in either direction.
9. Install the upper side rail. To install the side rail, first fit one end of the rail into the piston groove,
then press the remaining portion into the
position by finger. See illustration.
CAUTION: Use of a ring expander to expand the side rail end gap can break the side rail, unlike
other piston rings. Do not use any piston ring expander when installing tire side rail.
10. Install the lower side rail in the same procedure as described in step 9. 11. Make sure that the
side rails move smoothly in either direction.
12. Using a piston ring expander, fit No.2 and then No.1 piston ring into position.
NOTE: The ring end is provided with an identification mark. The No. 1 ring identification mark is
"1T", the No. 2 ring is marked "2T".
13. Install piston rings with identification mark facing up, to the piston crown side.
Page 6901

Locations
Keyless Entry Module: Locations
Control Unit Location Overall View
Control Unit Location Views C - I

Page 3852
NOTE: -
If the one-way clutch turns or locks in both directions, replace the one-way clutch.
- If the one-way clutch turns clockwise while it doesn't counterclockwise, the one-way clutch may
have been assembled in the reverse direction.
I. Seal ring installation. (2) 1. Apply ATF to the seal ring and attach it to the output shaft.
CAUTION: -
Do not bend the claw of the seal ring.
- Do not open the seal ring wider than necessary.
Second Brake
DISASSEMBLY
NOTE: Disassembly service points as follows:

Page 5495
2. Use the special tools to press-fit the needle bearing until it is flush with the knuckle end face.
CAUTION: Use care to prevent driving the needle bearing too far in.
B. Spacer installation. (2)
1. Apply multi-purpose grease to the knuckle attachment surface of the spacer. 2. Install the spacer
to the knuckle with the chamfered side toward the center of the vehicle.
C. Oil seal installation. (1)
1. Use the special tools to press-fit the new oil seal until it is flush with the knuckle end face. 2.
Apply multi-purpose grease to the inside and lip of the oil seal.
Specifications
Wheel Hub: Specifications
SERVICE SPECIFICATIONS
Front Hub:
Play In The Axial Direction

.......................................................................................................................................... 0.05 mm
(0.0020 inch) or less Turning Resistance
................................................................................................................................................. 0.3 -
1.3 Nm (2.6 - 11.3 inch lbs.)
Spring Scale Reading

.......................................................................................................................................................... 5
- 8 N (1.1 - 4.0 lbs.)
Page 754

Page 4764
Electronic Brake Control Module: Service and Repair

1. Remove the third rear seat from above the rear wheel wells, if necessary. 2. Remove the quarter
trim. 3. Refer to the illustration, and remove bracket "A." 4. Remove the bracket and the electronic
control unit. 5. Reverse procedure to install.
Page 3681
Control Unit: Electrical Diagrams

Rear Differential Lock System (Part 1 Of 2)
Page 1076
Fluid - M/T: Fluid Type Specifications
API classification GL-4 SAE 75W-85W, 75W-90
Oil Pressure Gauge: Diagram Information and Instructions
Page 2904
OPERATION
high to low.
Engine - Spark Knock/Ping Diagnostic's
Fuel: All Technical Service Bulletins Engine - Spark Knock/Ping Diagnostic's
SOURCE: Mitsubishi Tech-Talk Article, November 2004
TITLE: Engine Pinging
APPLIES TO: All Models
SERVICE TIP: When diagnosing an engine pinging condition, always check for carbon deposits,
which may have occurred due to fuel grade or quality and/or the customer's driving style. If
necessary, clean combustion deposits from the pistons and combustion chamber. Recommend to
customers to always use the correct grade of fuel for their model vehicle.
Page 1393
Piston: Service and Repair
REPLACEMENT
Refer to the illustration for the service procedure, noting the following:
Page 7154
RELAY VIEW
Defogger Relay H
Page 2313
Check that cycle time T becomes shorter and the frequency increases when the engine speed is
increased.
- Example 1 Cause of problem Malfunction of sensor interface
Short wave pattern is output even when the engine is not started.
- Example 2 Cause of problem Loose timing belt Abnormality in sensor disk
Wave pattern is displaced to the left or right.

Page 3390

Page 5162
Centralized Relay
Page 4712
Transmission Speed Sensor: Testing and Inspection Output Speed Sensor
INSPECTION
1. Disconnect the vehicle speed sensor connector. 2. Measure the resistance between terminals
No. 3 - 4 of the sensor-side connector.
Standard value: 620 +/- 60 ohms [at 20° C (68° F)]
3. If the resistance is outside the standard value, replace the vehicle speed sensor.
Rocker Arm Inspection
Rocker Arm Assembly: Testing and Inspection Rocker Arm Inspection
1. Check the roller surface and replace the rocker arm if recessary, damage or heat seizure is
observed. 2. Check roller rotation and replace the rocker arm if uneven rotation or roller backlash is
observed. 3. Check the inside diameter and replace the rocker arm if damage or seizure is
observed.
Page 2555
Specifications
Parking Brake Shoe: Specifications
Standard (New) 0.256 in
Minimum Thickness 0.177 in

Specifications
Receiver Dryer: Specifications
With part replacement add refrigerant oil. ND-OIL 8 ...........................................................................
.............................................................................................................. 10 cubic cm (0.3 fl. oz.)
Page 855
Neutral Safety Switch: Testing and Inspection

Page 5329
Power Steering Pump: Testing and Inspection Pressure Test
Relief Pressure Check
1. Disconnect the pressure hose from the oil pump, and then connect the special tools. 2. Bleed the
air, and then turn the steering wheel several times while the vehicle is not moving so that the
temperature of the fluid rises to
approximately 50 - 60° C (122 - 140° F).
3. Start the engine and idle it at (1,000 ± 100 rpm) 900 - 1,100 rpm. 4. Fully close the shut-off valve
of the pressure gauge and measure the oil pump relief pressure to confirm that it is within the
standard value range.
Standard value: 8.31 - 9.0 MPa (1,205 - 1,305 psi)
CAUTION: Pressure gauge shut off valve must not remain closed for more than 10 seconds.
5. If it is not within the standard value, overhaul the oil pump. 6. Remove the special tools, and the
tighten the pressure hose to the specified torque. 7. Bleed the system.
Checking Pressure Under No-Load Conditions
Page 7105
Turn Signal Lamp: Specifications Rear Combination Light
Turn-signal light ...................................................................................................................................
............................................................. 32 (1156) cp
NOTE : The values in parentheses denote SAE grade numbers.

Page 3439


Page 4934
(2) Make sure that the shaft of the special tool makes a light contact with the master cylinder
piston.
(3) Turn the wing bolt to secure the shaft.
(4) Using a hand vacuum pump, apply vacuum [-66.7 kPa (about 20 in. Hg)] to the brake booster.
(5) Position the special tool slightly off-center of the brake booster push rod as shown.
(6) Slide the special tool toward the center of the brake booster. Verify that the projection of the
shaft comes into contact with the end of the push rod of the brake booster as shown.
If the push rod contacts any portion of the shaft other than its projection, shorten the push rod.
If the push rod does not contact the shaft, lengthen the push rod.
Page 2799


Page 126
If you are using reprogramming information in a TSB that was issued before MUT-III
reprogramming capability became available, use the tables to determine the appropriate MUT-III
database number.
Page 899

Page 5987
Page 2101
Page 7060
APPLICABLE SERVICE GROUPS
NOTE:
Due to the number of applicable service manuals that this TSB applies to the individual page
numbers are not provided. Apply this TSB using the Group No. and Title as described.
With ABS
Brake Hose/Line: Service and Repair With ABS
REPLACEMENT
1. Drain the brake fluid. 2. Refer to the illustration and remove the sections of brake hose/brake
pipe sa necessary.
CAUTION: Do not disassemble the load sensing proportioning valve. Its performance depends on
the load of the spring.
3. Reverse procedure to install, noting the order the brake pipes are installed in.
- From master cylinder to hydraulic unit (rear brake).
- From master cylinder to hydraulic unit (front brake).
- From hydraulic unit to rear brake.
- From hydraulic unit to LH front brake.
- From hydraulic unit to RH front brake.
4. Ensure complete hydraulic system bleeding. See: Brake Bleeding/Service and Repair
Suspension Mode Switch: Testing and Inspection
INSPECTION
Operate the switch and check the continuity between the terminals.
Page 476
Wire Color Codes
the marking color.

Page 6358
Wire Color Codes
the marking color.

Page 4418

Page 4699
1996 Montero, Volume 1, pages 23A-19 and 23A-20. Refer to pages 10 and 11 of TSB-97-23-001.
Overdrive Planetary Gear and Overdrive Direct Clutch
Overdrive Assembly: Service and Repair Overdrive Planetary Gear and Overdrive Direct Clutch
DISASSEMBLY
A. Snap ring removal. (7)
INSPECTION
Specifications
EGR Valve: Specifications
Torque 16 ft.lb
Page 1224
Clutch Switch: Testing and Inspection
1. Disconnect the connector. 2. Check that there is continuity between the connector terminals
when the clutch pedal is depressed.
Specifications
Electronic Brake Control Module: Specifications
TIGHTENING SPECIFICATIONS
Bracket "A" Mounting Bolts ..................................................................................................................

............................................... 12 Nm (9 ft. lbs.)
Page 971
Idle Speed: Adjustments Fixed SAS Adjustment
NOTE:
1. The fixed SAS has been factory-adjusted. Never attempt to move it. 2. If the adjustment is
incorrect, adjust by following the procedure given below.
(1) Sufficiently slacken the accelerator cable. (2) Loosen the lock nut on the fixed SAS. (3)
Sufficiently loosen the fixed SAS by turning it counter clockwise to fully close the throttle valve. (4)
Turn the fixed SAS clockwise slowly to find a point at which it contacts the throttle lever (where the
throttle valve starts opening). From that
point, tighten the fixed SAS further 1 1/4 turns.
(5) While holding the fixed SAS to prevent it from turning, tighten the lock nut securely. (6) Adjust
the accelerator cable tension. (7) Adjust the basic idle speed. (8) Adjust the closed throttle position
switch and throttle position sensor (TPS).
Page 4211
THE FRICTION PLATE AND FRICTION DISC WEAR
1. In order to measure the wear, measure the thinkness of the friction surfaces and projections of
the friction disc and plate, and then find the
difference.
Limit: 0.1 mm (0.0039 inch)
NOTE: Make the measurements at several different points.
2. If the parts are worn beyond the allowable limit, replace them with new parts.
Assembly
Assembly in reverse order as disassembly.
A. Clutch plate friction force adjustment. (-)
Before assembly, use the following method to adjust the clearance between the spring plates and
the differential cases (for adjustment of the clutch plate friction force), and to adjust the end play of
the side gear when installing the internal components into the differential case.
1. Arrange the two friction discs and friction plates for each side one on top of the other as shown
in the illustration, so that the difference in
thickness between the left and right is at the standard value.
Standard value: 0.05 mm (0.0020 inch) or less.
NOTE: For new parts, there is one type of friction plate [1.9 mm (0.0689 inch)] and three types of
friction disc [1.9 mm (0.0748 inch), 2.0 mm (0.0787 inch) and 2.1 mm (0.0827 inch)].
2. Assemble the pressure ring's internal components (different pinion shaft and pressure ring) and
the friction discs and friction plates, and
then measure the overall width as shown in the illustration.
3. Calculate the total value (C) of the thickness of the plate plus the value measured in 2 above. 4.
Obtain the dimension (D) between the spring plate contact surfaces when differential cases (A) and
(B) are combined. (D = E + F - G)
Page 5122
RELAY VIEW
Accessory Socket Relay G

Page 6547
Dimmer Switch: Electrical Diagrams

Oil Pressure, Fuel, Maintenance Required, Brake And Seat Belt Warning Lights (Part 1 Of 2)
Page 5617
Wheels: Testing and Inspection
WHEEL RUNOUT CHECK
Jack up the vehicle so that the wheels are clear of the floor. While slowly turning the wheel,
measure wheel runout with a dial indicator. Limit:
Radial runout: 1.0 mm (.04 inch) Lateral runout: 1.0 mm (.04 inch)
If wheel runout exceeds the limit, replace the wheel.

Page 5918
Step 2/3: Front Impact Sensor (R.H.)/front Impact Sensor (l.H.) Removal 1. Slide the connector
(green section) to release the lock. 2. Push down the pawl, and then disconnect the connector.
PRE-INSTALLATION INSPECTION
To mount the new front impact sensor, visually check it and measure the resistance between the
terminals.
Step 3/2: Front Impact Sensor (L.H.)/front Impact Sensor (R.H.) Installation 1. Securely connect the
connector. 2. Set the front impact sensor towards the front of the vehicle as shown by the arrow in
the illustration, and install it securely.
CAUTION: The SRS may not activate properly if a front impact sensor is not installed properly,
which could result in the SRS system not operating properly during a collision.
POST-INSTALLATION INSPECTION
Reconnect the negative battery terminal. Turn the ignition key to the "ON" position. Does the "SRS"
warning light illuminate for about 7 seconds, turn off and then remain off for at least 45 seconds? If
yes, SRS system is functioning properly. If no, consult SRS Warning Light Inspection.
INSPECTION
1. Check upper frame and sensor brackets for deformities or rust. 2. Check sensor harness for
binds, connectors for damage, and terminals for deformities. 3. Check for dents, cracks,
deformation or rust of the front impact sensor.
CAUTION: If a dent, crack, deformation or rust is detected, replace with a new sensor.
4. Measure the resistance between terminals and check whether it is within the standard value.
Page 601

Page 6067
--> Failure to submit the completed Speaker Complaint Checklist subjects the claim to debit.
Page 795
Wire Color Codes
the marking color.

Page 6479
Page 2561
Page 662

Page 2498
on actual vehicles.
Wire Color Codes
Page 4797
1. Turn up the carpet under the brake pedal. 2. Start the engine, depress the brake pedal with
approximately 500 N (110 lbs.) of force, and measure the clearance between the brake pedal and
the
firewall. The standard value (C) is 100 mm (3.94 inch) or more.
3. Turn back the carpet.

Page 2442
on actual vehicles.
Wire Color Codes
Page 4064

Page 6777
Temperature Gauge: Service and Repair
Refer to the illustration for service.

Locations
Manifold Pressure/Vacuum Sensor: Locations

SENSOR VIEW
Manifold Differential Pressure Sensor D

Page 793


Locations
Door Lock Relay: Locations

Locations
Starter Relay: Locations

Specifications
Cruise Control Indicator Lamp: Specifications
Cruise control indication light ...............................................................................................................
..................................................................... 1.12 W
Throttle Position Sensor: Diagram Information and Instructions
Page 1903
These components are required:
CONNECTING COMPONENTS
1. Insert the memory card into the PC card adapter. Then install into the VCI main unit.
2. Connect the MUT-III main harness A or B to the VCI main unit.
3. With the ignition switch in the OFF position, connect the MUT-III main harness to the data link
connector.
NOTE:
Page 2748
Barometric Pressure Sensor: Description and Operation
OPERATION
- The barometric pressure sensor functions to convert the barometric pressure to voltage, and to
input that voltage (as signals) to the engine control module. The engine control module based upon
those signals, then corrects the amount of fuel injection, etc.
- The 5 V power supply within the engine control module is supplied to the barometric pressure
sensor; it passes through the circuitry within the sensor, and is grounded at the engine control
module.
- The barometric-pressure sensor output voltage is supplied to the engine control module in
proportion to the barometric pressure (absolute pressure).
Page 2196
Page 2802
Page 2255
HARNESS INSPECTION
STEP 1. Check for continuity between the volume air flow sensor and the MFI relay. -
MFI relay connector: Disconnected
- Volume air flow sensor connector: Disconnected
NOTE: -
Touch the ohmmeter probes to both ends of the harness.
OK: GO TO STEP 2 NG: Repair the harness. (A4 - B1)
Volume air flow sensor connector: Disconnected OK: GO TO STEP 3 NG: Repair the harness. (A5
- 92)
STEP 3. Check for an open or short-circuit between the volume air flow sensor and the engine
control module. -
(A3 - 90, A7 - 19)
STEP 4. Measure the applied voltage -
- Engine control module connector: Connected

Page 869


Page 2488
Voltage (V): 4.5 - 4.9 V OK: STOP NG: Replace the engine control module.
ENGINE COOLANT TEMPERATURE SENSOR CHECK
(1) Remove the engine coolant temperature sensor from the intake manifold.
(2) With temperature sensing portion of coolant temperature sensor immersed in hot water check
resistance. Standard value: (3) If the resistance is outside the standard value greatly, replace the
sensor.
(4) Apply specified sealant to the threaded portion.
Specified sealant: 3M Nut Locking Part No. 4171 or equivalent
(5) Install the engine coolant temperature sensor and tighten it to the specified torque.
Sensor tightening torque: 30 Nm (22 ft.lbs)

Page 1540
Multi Meter (Part 2 Of 2)

Page 820
- Touch the ohmmeter problems to both ends of the harness. OK: GO TO STEP 2 NG: Repair the
harness. (A3 - B1)
Crankshaft position sensor connector: Disconnected OK: GO TO STEP 3 NG: Repair the harness.
(A1 - Ground)
STEP 3. Check for an open circuit or a short-circuit to ground between the crankshaft position
sensor and the engine control module. -
Engine control module connector: Disconnected
- Crankshaft position sensor connector: Disconnected OK: GO TO STEP 4 NG: Repair the
harness. (A2 - 89)
STEP 4. Measure the applied voltage. -
Crankshaft position sensor connector: Disconnected
- Ignition switch: ON Voltage (V): 4.8 - 5.2 OK: STOP NG: Replace the engine control module.
Page 4448
Page 3118
on actual vehicles.
Wire Color Codes
Page 1204
SNOW TIRE RECOMMENDATIONS FOR 1997 MODELS
Page 4123
15. While pushing the plug with a finger, use a magnet to remove the key.
16. Remove the plug, cutback valve and spring.
18. Remove the plug, spring and 2-3 shift valve.
19. While pushing the plug with a finger, use a magnet to remove the seat.
20. Remove the plug, spring and low coast modulator valve.
Inspection
Page 2955

Page 1369
To operate the block heater, attach the power cord to the block heater electrical connector and
route it safely inside the engine compartment. Plug the male end of the power cord into a standard
120V household electrical outlet. When operated overnight, the block heater will help prevent
engine coolant from thickening and/or freezing. This allows the engine to start and run normally in
very cold ambient temperatures.
Engine Core Plug Locations
Refer to the illustrations along with the application chart in this bulletin to identify engine core plug
locations and block heater installation position.
Block Heater Element Location and Direction
NOTE:
Position indicated by direction of the heater coils, not the electrical connector.
Block Heater Installation
!WARNING
To avoid personal injury, be sure to safely release the pressure from the cooling system and drain
the coolant before installing the block heater.
In addition to the instructions supplied with the block heater, refer to the following installation and
usage procedures:
1. Locate the appropriate core plug location and remove the core plug (see above). Do not attempt
to install the block heater in a core plug location not specified in this bulletin.
2. Lubricate the O-ring with clean engine coolant.
3. Insert the block heater with the heating element pointed in the proper direction as indicated on
the application chart in this bulletin.
4. Tighten the block heater screw to the exact torque specified in the installation instructions.
5. Firmly attach the power cord to the block heater. Route the cord away from hot or moving parts
in the engine compartment.

Switch Adjustment
V4AW2 A/T.
23A-45
Page 2857
Manifold Pressure/Vacuum Sensor: Description and Operation
NOTE: Federal vehicles only.
OPERATION
- The manifold differential pressure sensor converts air pressures in the intake manifold plenum
into voltage signals and send them to the engine control module. The engine control module
monitors the EGR system using this signals and generates the diagnostic trouble code if there is an
abnormality in the EGR system.
- 5 V of power is supplied to the manifold differential pressure sensor from the engine control
module, and the sensor circuit ground is located in the engine control module.
- The manifold differential pressure sensor output voltage is proportioned to the intake manifold
plenum pressure and sent to the engine control module.
Page 4891
Hydraulic Assembly: Testing and Inspection
HU (MOTOR) CHECK
1. Jack up the vehicle and support it on axle stands. 2. Release the parking brake and feel the drag
force (drag torque) on each wheel brake. See: Brake Caliper/Testing and Inspection 3. Connect the
scan tool to the data link connector.
CAUTION: Turn the ignition switch "OFF" before connecting or disconnecting the scan tool.
4. After checking that the selector lever is in neutral, start the engine.
CAUTION: At this time, check that the ABS warning light illuminates for a brief period before
turning off, if not, refer to "Inspection Chart For Trouble Symptoms." See: Antilock Brakes / Traction
Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview
5. Depress the brake pedal to lock the wheels. 6. Select the item number on the scan tool actuator
test for the wheel to be inspected.
- Item 1 drives the front left wheel.
- Item 2 drives the front right wheel.
- Item 3 drives the rear wheels.
7. Use the scan tool to force-drive the actuator, and turn the wheel by hand to check the change in
braking force when the brake pedal is depressed.
The result should be as shown in the illustration.
NOTE: -
When the scan tool is used and the ABS system is selected, the ABS system will switch to scan
tool mode and the ABS warning light will illuminate.
- When the ABS function has been interrupted by the fail-safe, the scan tool actuator testing cannot
be used.
Overdrive Switch: Testing and Inspection
INSPECTION
Check for continuity between the terminals when the switch is turned off and on.
Page 6359
Seat Heater: Electrical Diagrams
Heated Seat (Part 1 Of 2)

Page 5896
Air Bag Control Module: Locations

Page 6590

Service and Repair
Fuel Pressure Release: Service and Repair
When removing the fuel pipe and hose, etc., fuel under high pressure will be inside the fuel line, so
carry out the following procedure to release the pressure to prevent the fuel from spraying out.
1. Take out the carpet in the cargo compartment and remove the floor cover.
2. Disconnect the fuel pump unit connector. 3. After starting the engine and letting it run until it
stops, turn the ignition switch to OFF. 4. Connect the fuel pump unit connector. 5. Install the floor
cover packing and the floor cover.
Page 2742
Grounding Markings

Drive Belt Tension Check and Adjustment
Drive Belt: Testing and Inspection Drive Belt Tension Check and Adjustment
CHECKING
Check the belt tension by using a belt tension gauge or by applying 98 N (22 lbs.) of force to the
belt midway between the pulleys as shown in the illustration, and measure the deflection. The
values are as shown in the illustration.
NOTE: A: Measure between the water pump pulley and the crankshaft pulley. B: Measure between
the water pump pulley and the generator.
Page 5818
Cabin Temperature Sensor / Switch: Testing and Inspection
INSPECTION
INTAKE AIR TEMPERATURE SENSOR AND AIR INLET SENSOR
When the resistance value between the sensor terminals is measured under two or more
temperature conditions, the resistance value should be close to the values shown in the graph.
NOTE: The temperature conditions when testing should not exceed the range of the characteristic
curve in the graph.
TESTING
1. Disconnect the sensors connector at the evaporator case and then use an ohmmeter to measure
the resistance. It the resistance is within 10% of the
value on the characteristic curve, the sensor is functioning normally.
2. If the sensor is normal, there is a malfunction of the air conditioning control unit and it should be
replaced.
Power Antenna - Motor Inspection Procedure Revisions
Antenna Control Module: Technical Service Bulletins Power Antenna - Motor Inspection Procedure
Revisions
NO.: TSB-97-54-002 Date: January, 1997 Model: 1992-97 Montero
Subject: CORRECTED MOTOR ANTENNA AND CONTROL UNIT INSPECTION PROCEDURES -

PURPOSE This bulletin corrects motor antenna and motor antenna control unit inspection
procedures. These corrected procedures involve plug, pin, and terminal configuration and
numbering.
affected service manual page.
AFFECTED VEHICLES 1992-97 Montero
AFFECTED MANUALS 1992-95 Montero Service Manual, Volume 2, Page 54-144 1996 Montero
Service Manual, Volume 2, Page 54-115 1997 Montero Service Manual, Volume 2, Page 54-78
SERVICE MANUAL REVISIONS

Page 2643
on actual vehicles.
Wire Color Codes
Page 5500
CONTROL UNIT SIGNAL CIRCUIT INSPECTION
1. Disconnect the shock absorber control unit connector, and inspect the connector at the harness
side.
2. Connect the shock absorber control unit and inspect.
NOTE: B+ is battery positive voltage.

Page 2465
Camshaft Position Sensor: Oscilloscope Patterns and Waveforms
INSPECTION
Wave Pattern Inspection using an Analyzer Measurement method (1) Disconnect the connector of
the camshaft position sensor, and connect the special tool (test harness: MB991348) across the
disconnected
connector parts. (Connect the tool to all terminals.)
(2) Connect the special patterns pickup of the analyzer to the terminal (2) of the camshaft position
sensor connector. (3) Disconnect the connector of the crankshaft position sensor, and connect the
special tool (test harness: MD998478) across the disconnected
connector parts.
(4) Connect the special patterns pickup of the analyzer to the terminal (2) of the crankshaft position
sensor connector.
Alternative method (when test harness is not available)
(1) Connect the analyzer special patterns pickup to ECM terminal (88) for the camshaft position
sensor. (2) Connect the analyzer special patterns pickup to ECM terminal (89) for the crankshaft
position sensor.
Standard wave pattern
Observation conditions

Page 4823
5. Remove the piston seal and caliper body. Remove piston seal with finger tip.
CAUTION: Do not use a screwdriver or other tools in order to prevent damage to the inner cylinder.
NOTE: Clean the piston surface and the inner cylinder with trichloroethylene, alcohol, DOT 3 or
DOT 4 brake fluid.
6. Reverse procedure to install, noting the following:
7. Install the guide pin and lock pin as shown in the illustration so that each head mark of the guide
pin and the lock pin matches the indication mark
(G or L) located on the caliper body.
Rear
Page 1618
Oil Pressure Warning Lamp/Indicator: Description and Operation
- This warning light illuminates when the ignition switch is at the ON position, and switches off after
the engine has started. This indicator illuminates when the oil fails or a problem occurs in the oil
circulating system while driving.
Page 734

Page 2789
Coolant Temperature Sensor/Switch (For Computer): Service and Repair

Page 5916
Sensor Location Views I - R
SENSOR VIEW
Front Impact Sensor (L.H.) I
Front Impact Sensor (R.H.) K

Page 2264
Grounding Markings

Page 4196
3. Install the drive pinion assembly and companion flange with the mating marks properly aligned,
and then use the special tools to tighten the
companion flange self-locking nut to the specified torque.
4. If the drive pinion rotation torque is not within the rage of the standard value, adjust the rotation
torque by replacing the drive pinion front
shim(s) or the drive pinion spacer.
Standard value:
New (with anti-rust agent): 0.85 - 1.15 Nm (7.4 - 10.0 inch lbs.) New/reused (gear oil applied): 0.65
- 0.75 Nm (5.6 - 6.5 inch lbs.)
E. Drive gear installation. (23)
1. Clean the drive gear mounting bolts.
2. Remove the adhesive which is adhering to the threaded holes of the drive gear by turning the
tap tool (M12 x 1.25), and then clean the
threaded holes by applying compressed air.
3. Apply specified adhesive to the threaded holes of the drive gear.
Specified adhesive: 3M Stud Locking Part No. 4170 or equivalent.
4. Install the drive gear to the differential case so that the mating marks are properly aligned.
Tighten the bolts to the specified torque in a
diagonal sequence.
F. Side bearing inner race installation. (26)

Page 2959
Differential Whine - Revision
Drive/Propeller Shaft: All Technical Service Bulletins Differential Whine - Revision
NO: TSB-99-27-001 DATE: June, 1999 MODEL: 1995-99 Montero
SUBJECT: DIFFERENTIAL WHINE
This bulletin supersedes TSB-98-27-001 dated June, 1998, which should be discarded. New and/or
revised information is marked by **.
PURPOSE
This bulletin has procedures for eliminating or reducing an apparent differential whining noise on
affected 1995-99 Montero vehicles.
Symptom
The customer may complain of a whine coming from the differential at speeds generally between
50 to 60 mph during light acceleration or when coasting in gear.
Cause
The whining noise may be attributed to differential noises being transmitted through the body
and/or out-of-specification tolerances in the differential itself.
Remedy
Follow the procedures in this bulletin to first test drive the vehicle to assess the severity of the
whining noise. Procedures are included for the following repair steps:
1995-97 MODEL YEAR MONTERO
^ Replace the propeller shaft with a birfield joint (BJ-type) and damper.
^ Apply sound reduction sheets to the floorpan of the vehicle body (under the interior carpet) in the
the rear footwell area, under the rear seat area, and under the rear cargo area floor.
^ Replace the indicated six rubber body mounts.
** ^ Install rear suspension trailing arm dampers on each side of the vehicle.
** ^ Install new upper spring seats on each rear spring.
**1998-99 MODEL YEAR MONTERO (built before 8/25/98)
^ Replace the propeller shaft with a long-yoke BJ-type.
^ Install rear suspension trailing arm dampers on each side of the vehicle.
^ Install new upper spring seats on each rear spring.
**1999 MODEL YEAR MONTERO (built after 8/25/98)
^ In severe cases, replace the differential assembly.
NOTE:
Prior Work Authorization (PWA) from your DPSM is required prior to any differential replacement.
Page 134


Page 725
Vehicle Speed Sensor: Description and Operation
OPERATION
- The vehicle speed sensor is incorporated within the speedometer; it converts vehicle speed data
to pulse signals and inputs those signals to the engine control module. The engine control module,
based upon those signals, regulates the idle air control motor, etc.
- The vehicle speed sensor, by intermitting by the lead switch the flow (to ground) of the
approximately 5 V voltage applied from the engine control module, produces vehicle speed signals.
Specifications
Compressor Clutch: Specifications AIR GAP
AIR GAP
0.35-0.66 M.M. 0.014-0.026 In.

Locations
Diagnostic Connector - Fuel Pump: Locations
Inspection Terminal Location Overviews And Views A - B
COMPONENT VIEW VIEW
Fuel Pump Check connector A

Page 5898
Air Bag Control Module: Testing and Inspection
To inspect and service the SRS after a collision (whether or not the air bags has deployed),
perform the following steps.
SRS AIR BAG CONTROL UNIT MEMORY CHECK
1. Connect the scan tool to the data link connector then check diagnosis codes.
CAUTION: Turn the ignition switch off before connecting or disconnecting the scan tool.
2. Read (and write down) all displayed diagnostic trouble codes.
NOTE: If the battery power supply has been disconnected or disrupted by the collision, the scan
tool cannot communicate with the SRS diagnosis unit. Inspect and, if necessary, repair the body
wiring harness before proceeding further.
3. Read the service data (fault duration and how many times the memory was erased) using the
scan tool.
NOTE -
Maximum stored period: 9999 minutes (approximately 7 days)
- Maximum number of times to be stored: 250
4. Erase the diagnostic trouble codes then wait 45 seconds or more, read and write down all
displayed diagnostic trouble codes.
Page 6268
Grounding Markings

Page 3721


Page 5353
POWER STEERING PRESSURE SWITCH CHECK
3. The engine should be idling. 4. Disconnect the connection of the connector for the pressure
switch, and place an ohmmeter in position. 5. Gradually close the shut-off valve of the pressure
gauge and increase the hydraulic pressure then check whether or not the hydraulic pressure that
activates the switch is the standard value.
Standard value: 1.47 - 1.96 MPa (213 - 284 psi)
6. Gradually open the shut-off valve and reduce the hydraulic pressure; then check whether or not
the hydraulic pressure that deactivates the switch is
the standard value.

7. Remove the special tools, and then tighten the pressure hose to the specified torque. 8. Bleed
the system.
Air Conditioning Control Unit
Control Assembly: Service and Repair Air Conditioning Control Unit

Page 2941
7. When not using the scan tool, proceed as follows.
1) Connect the special tool (test harness set) between the disconnected throttle position sensor
connectors. (Connect all terminals, while being
careful not to mistake the terminal numbers.)
2) Connect a digital voltmeter between the throttle position sensor terminal 3 (sensor output) and
terminal 1 (sensor ground.) 3) Turn the ignition switch ON (but do not start the engine).
8. Check the throttle position sensor output voltage.
Standard value: 400 - 1,000 mV
9. If the voltage is outside the standard value, check the throttle position sensor and associated
harnesses.
10. Remove the feeler gage. 11. Turn the ignition switch to OFF.
Specifications
Compression Check: Specifications
Compression Pressure at 250 - 400 rpm
Standard ..............................................................................................................................................
........................................... 1200 kPa (171 psi) Service limit ..............................................................
....................................................................................................................... 890 kPa (127 psi)
Difference between cylinders (max)
.................................................................................................................................................. 100
kPa (14 psi)
Specifications
Acceleration/Deceleration Sensor: Specifications
Bracket Bolt .........................................................................................................................................

............................................... 13 Nm (9.4 ft. lbs.) Sensor Mounting Nut ............................................
............................................................................................................................... 5 Nm ( 3.6 ft. lbs.)
Page 4918
Parking Brake Lever: Adjustments
LEVER STROKE
Ensure that the standard value is 4 - 6 notches. If the parking brake lever stroke is not within the
standard value range, make necessary adjustments by the following procedures: 1. Loosen the
adjuster to slacken the parking brake cable
2. Remove the adjustment hole plug, and then use a flat-tip screwdriver to turn the adjuster in the
direction of the arrow (the direction which expands
the shoe) so that the disc will not rotate.
3. Return the adjuster 3 - 4 notches in the direction opposite to the direction of the arrow. 4. Turn
the adjusting nut to adjust the parking brake lever stroke to within the standard value range.
CAUTION: If the number of brake lever notches engaged is less than the standard value, the cable
has been pulled excessively. Be sure to adjust it to within the standard value.
5. After making the adjustment, check that there is no play between the adjusting nut and the pin.
Also, check that the adjusting nut is securely held at
the nut holder.
6. After adjusting the lever stroke, jack up the rear of the vehicle. 7. With the parking brake lever in
the released position, turn the rear wheel to confirm that the rear brakes are not dragging.
Page 3529
on actual vehicles.
Wire Color Codes
Page 2570
Sensor Location Views R - Z
SENSOR VIEW
Fuel Tank Differential Pressure Sensor U

Page 1922
on actual vehicles.
Wire Color Codes
Engine Controls - PCM Reprogramming Procedure
Technical Service Bulletin # 03-00-015 Date: 030901
No: TSB-03-00-015 DATE: September, 2003 MODEL: All models
SUBJECT: REPROGRAMMING WITH THE MUT-III
PURPOSE
This bulletin contains general instructions for reprogramming a vehicle PCM using the MUT-Ill
vehicle communication interface (VCI) unit. Before beginning reprogramming, you must first
transfer the reprogramming data to a PC memory card adapter equipped with a compact flash
memory chip. New data is transferred from a DVD to the PC hard drive, then to the PC memory
card. After data is in the memory card, it can be downloaded to the VCI, then to the vehicle's PCM
(ECU).
The MUT-III is capable of both automatic reprogramming (it automatically selects the appropriate
database) and manual reprogramming (you select the database). Automatic reprogramming is
recommended for most typical reprogramming situations. If automatic reprogramming is not
successful, try manual reprogramming.
AFFECTED VEHICLES
All models capable of PCM reprogramming, except 1995-99 Eclipse 2.0L non-turbo (For 1995-99
Eclipse 2.0L non-turbo models, use M1T992000-A and refer to the applicable TSB.)
I. Transferring Reprogramming Data to Memory Card

Page 1918

Page 1353
Crankshaft Main Bearing: Specifications
Main Bearing Cap 74 Nm

Page 1710
Spark Plug: Application and ID
Spark plug ID
NGK .....................................................................................................................................................
................................................................PFR5J-11
Denso ..................................................................................................................................................
............................................................PK16PR-P11
Page 5796
Condenser Fan Motor Relay: Testing and Inspection
1. Remove the condenser fan motor relay and compressor relay from the relay box at the left of the
engine compartment. 2. Use an ohmmeter to check for continuity between the terminals.
Page 2934
on actual vehicles.
Wire Color Codes
Page 2576


Transmission Position Switch/Sensor: Diagram Information and Instructions
Specifications
Idle Speed: Specifications IDLE SPEED
IDLE SPEED
Controled Idle Speed
700 RPM Man & Auto

Page 5687
Condenser HVAC: Service and Repair
>A< CONDENSER INSTALLATION
When replacing the condenser with a new one, refill the condenser with a specified amount of
compressor oil and install it (to the vehicle). Compressor oil: ND-OIL 8 Quantity: 40 cubic cm (1.4
fl.oz.)
Page 5630
4. If the amount of play is outside the standard value, adjust by selecting a shim that will bring the
play to the standard value.
Page 6344
1997 Montero Service Manual, Volume 2, Page 191 Replace the circuit diagram crossed-out on the
previous page of this bulletin with the new corrected diagram shown.
Page 3527

Page 3168
Grounding Markings

Component Tests and General Diagnostics
Ignition Control Module: Component Tests and General Diagnostics
Ignition Power Transistor Check
NOTE: An analog-type circuit tester should be used.
Ignition Power Transistor
Ignition Power Transistor - Chart
No. 1 - No. 4 coil side
1. Connect the negative (-) terminal of the 1.5 V power supply to terminal (4) of the ignition power
transistor and then check whether there is
continuity between terminal (13) and terminal (4) when terminal (3) and the positive (+) terminal are
connected and disconnected.
NOTE: Connect the (-) probe of the circuit tester to terminal (13).
2. Replace the ignition power transistor if there is a malfunction.
transistor, and then check whether there is

Diagrams
Joint Connector (J/C)

Page 3803
Automatic Transmission Overhaul Service Manual, Page 23F-13: Add the new forward clutch
piston stroke measuring tool as shown.
Page 4584
INSTALLATION
Installation in reverse order as removal.
NOTE: Installation service points as follows:
A. Shift lock cable connection (brake pedal side). (28)
1. Install the shift lock cable to the brake pedal, and clamp the brake support member with the nut.
2. Route the shift lock cable correctly.
CAUTION: Do not change the routing of the shift lock cable to the selector lever assembly.
B. Slide lever/key interlock cable (steering lock assembly side)/cam lever installation. (23, 24 & 25)
1. Place the ignition key at the LOCK position or keep it removed. 2. Install the slide lever, key
interlock cable and cam lever to the steering lock assembly as shown in the illustration.
CAUTION: Do not change the routing of the key interlock cable to the selector lever assembly.
C. Cable band installation. (21)
Place the shift lock cable and key interlock cable as shown in the illustration, and clamp them with
the cable band.
D. Transfer control lever assembly installation. (13)
1. Remove the adhesive which is sticking to the transfer control lever assembly mounting bolts. 2.
Use a tap (M8 x 1.25) to remove the adhesive which is sticking to the screw mounting holes in the
transfer control lever assembly.
Page 5013
1996 Montero, Volume 1, page 23A-44

Locations

Page 3178
Page 2179
Throttle Full Close Switch: Testing and Inspection
TROUBLESHOOTING HINTS If there is an abnormal condition of the closed throttle position switch
output even though the results of the checking of the closed throttle position switch harness and of
the component itself indicate a normal condition, the cause is probably one of the following.
- Voltage within the engine control module is applied, by way of the resistance, to the closed
throttle position switch. When the foot is taken off the accelerator, the closed throttle position switch
is switched ON, so the current is grounded. As result, the closed throttle position switch terminal
voltage changes from HIGH to LOW level. (1) Incorrect adjustment of the accelerator cable or the
cruise-control cable. (2) Incorrect adjustment of the fixed SAS.
Page 4060
Transmission Position Switch/Sensor: Locations
Other Devices Location Overviews
Other Devices Location Views C - G

Locations
Heated Glass Element Relay: Locations

Page 6074
Use the flowcharts to diagnose suspected speaker related audio system conditions:
PARTS INFORMATION
For the best performance from a Mitsubishi factory-installed audio system, use the genuine
Mitsubishi original equipment speaker for replacement. Refer to CAPS for correct part numbers.
This bulletin is for information only, not warranty authorization. Normal warranty procedures apply.
Page 3056
SENSOR VIEW
Reed Switch L
Page 5595
Wheel Hub: Service and Repair Overhaul
DISASSEMBLY
A. Brake disc removal. (5)
Make mating marks on the brake disc and front hub, and then separate the front hub and brake
disc, if necessary.
CAUTION: Lock the disc in a vise and grip it with a copper or aluminum board.
BEARING REPLACEMENT
1. Wipe off any grease on the inside surface of the front hub.
Page 4335
1. Referring to section 34 in the service manual, replace the trailing arm damper on both sides of
the vehicle.
2. Using the instructions in section 34 of the service manual, replace the upper spring seat on both
rear springs.
DIFFERENTIAL REPLACEMENT (1995-99 MODELS)
If you determine that the differential assembly requires replacement, use the differential removal
and replacement procedures in section 27 of the service manual.
NOTE:
PWA from your DPSM is required prior to any differential replacement.
** PARTS INFORMATION
Page 2541
This message displays if there is a communication problem. Turn the ignition switch to OFF and
retry.
ECU check error
This message displays if the memory card data does not match the ECU data. Press ENTER to
update the ECU with the memory card data.
D/B incorrect, reinstall D/B
This message displays if the data in the memory card is not appropriate for the PCM. Press
ENTER to return to the main menu. Remove the memory card from the VCI and install in the
MUT-III PC, then retry data transfer.
CK VNxxxxxx; No Data
This message displays if there is no reprogramming data in the memory card. Press ENTER to
return to the main menu. Remove the memory card from the VCI and install in the MUT-III PC, then
retry data transfer.
IV. Warranty Information
PCM reprogramming based on customer complaint or recall only. Use the appropriate PCM
reprogramming labor operation listed in the applicable TSB.
Labor time for updating ROM packs is no longer applicable.
Attachment A
ATTACHMENT A - RN to VN Database Numbers

Page 1391
Piston: Specifications
DIMENSIONS
Outer Diameter ....................................................................................................................................

.............................................. 93.0 mm (3.66 inch) Piston/Cylinder Clearance
..................................................................................................................................... 0.03 - 0.05
mm (0.0012 - 0.0020 inch)
Page 5865
1997 Mirage Service Manual, Volume 1, Page 52B-15 Add the new SRS troubleshooting
Page 2248


Page 1776

Electrical Specifications
Suspension Strut / Shock Absorber: Electrical Specifications
Variable shock absorber indication light
.................................................................................................................................... Light Emitting
Code (LED)
Page 5382
Page 1318
Rocker Arm Assembly: Specifications
Mounting Bolts .....................................................................................................................................

............................................... 31 Nm (23 ft. lbs.)
Page 4188
A. Side bearing nut removal. (2)
Use the special tool to remove the side bearing nut.

Page 4841
1997 Montero Sport Service Manual, Volume 1, Page 27-2 Add the new service specification as
shown.
Page 7159
RELAY VIEW
Power Window Relay H


Page 3420
(2) Turn the throttle position sensor 900 counterclockwise to set it, and tighten the screws.
(3) Connect a circuit tester between terminals 1 (ground) and 3 (output), or between terminals 3
(output) and 4 (power). Then, make sure that the
resistance changes smoothly when the throttle valve is slowly moved to the fully open position.
(4) Check for continuity between terminals 2 (closed throttle position switch) arid 1 (ground) with
the throttle valve both fully closed and fully
open. If there is no continuity with throttle valve fully closed, turn the throttle position sensor
clockwise, and then check again.
(5) If the above specifications are not met, replace TPS.

Fuel Level Sensor: Testing and Inspection
Fuel Level Sensor Check
Connect the fuel gage unit to the battery via a test light (12 V - 3.4 W), and then immerse the fuel
gage unit in water. The condition is good if the test light switches off when the fuel gage unit
thermistor is in water and illuminates when the thermistor is removed from the water.
CAUTION: After completing this test, wipe the unit dry and install it to the fuel tank.
Page 3325
1999 Montero Service Manual, Volume 1, Page 13A-92 Correct the illustration for Step 3 as shown:

Page 5458
2. Apply multipurpose grease to both the interior of dust cover and the upper ball joint.
INSTALLATION
a. Upper arm installation.
Install the upper arm so that the "OUT" mark on the upper arm shaft is facing toward the outside of
the vehicle.
b. Shock absorber/actuator (vehicles with remote controlled variable shock absorber) installation.
Tighten the shock absorber installation nut so that the dimensions shown in the illustration (A and
B) are at the standard values. Standard value:
A: 1 - 2 mm (.04 - .08 inch) B: 1.5 - 2.5 mm (.06 - .10 inch)
CAUTION: When tightening the nut, be careful not to bend the stud pin of the washer assembly.
c. Operational steps after installation as follows:

Page 871
Wire Color Codes
the marking color.

Page 686
Throttle Position Sensor: Description and Operation
OPERATION
- The throttle position sensor functions to convert the degree of opening of the throttle valve to
voltage, and to input that voltage (as signals) to the engine control module. The engine control
module, based upon those signals, then regulates the amount of fuel injection, etc.
- The 5 V power supply within the engine control module is supplied to the throttle position sensor,
after which it passes through the resistance within the sensor and is grounded as the engine
control module.
- When the throttle valve shaft is rotated all the way from the idling position to the fully open
position, the resistance between the throttle position sensor's variable-resistance terminal and the
ground terminal also increases in accordance with that rotation, and, as a result, the voltage of the
throttle position sensor's variable-resistance terminal also becomes higher in accordance with that
rotation.
Locations
Blower Motor Relay: Locations

Page 4007
Shift Solenoid: Testing and Inspection Shift Solenoid No. 2
INSPECTION
1. Disconnect the shift solenoid connector. 2. Measure the resistance between terminal No. 7 and
the ground.
3. If the resistance is outside the standard value, replace the solenoid assembly.
Page 5267
Power Steering Pressure Switch: Testing and Inspection
INSPECTION
Using Scan Tool
Checking Fluid Pressure

HARNESS INSPECTION
STEP 1. Check for an open or short-circuit between the power steering pressure switch and the
engine control module. -
Power steering pressure switch connector: Disconnected
(A1 - 37)
- Ignition switch: ON Voltage (V): Battery positive voltage OK: STOP NG: Replace the engine
control module.
Page 1728
Water Pump: Service and Repair
1. Drain the engine coolant. 2. Remove the timing belt. 3. Refer to the illustration for the service
procedures, noting the following:
- When installing the O-ring, rinse the mounting location of the O-ring and water pipe with water,
and install the O-ring and water pipe.
NOTE: -
Do not apply oil and grease to water pipe O-ring.
- Keep the water pipe connections free of sand, dust etc.
- Insert water pipe until its end bottoms.

Page 3392
on actual vehicles.
Wire Color Codes
Page 1054
2. Connect the pressure hose so that its slit part contacts the oil pump guide bracket.
NOTE: Operational steps after installation as follows: 1. Fill power steering fluid. 2. Bleed Power
steering fluid line. See: Steering and Suspension/Steering/Service and Repair
Page 5760
6. If the refrigerant's pressure is higher than the limit shown for a given temperature, slowly vent
the vapor from the top of the container into the recovery/recycling unit. Continue until the pressure
falls below the limit shown in the R12 or R134a chart. If the refrigerant is R134a and the pressure
still exceeds the limits shown in the chart, shake the container and let it stand for several minutes.
If the pressure then falls below the limits, it is OK to use as is. Should the pressure inside the
container still exceed the pressure limit shown, recycle the entire contents.
System Flushing
Now that CFCs cannot legally be vented to the atmosphere, flushing compounds such as R11 and
R113 are no longer viable for flushing systems. To flush oil out of an R12 system when retrofitting
for RI34a, you can use a recycling machine and liquid R12, which picks up the mineral oil used with
R12 and takes it out. Do not use flammable solvents like mineral spirits or lacquer thinners. They
are fire and explosion hazards.
Typical Cause of A/C System Contamination
Following are the most probable causes of contamination in automotive A/C systems:
^ Mixing refrigerants
^ Contaminated service equipment
Mixing Refrigerants
Under no circumstances should a system be charged with any refrigerant other than the refrigerant
specified on the labels on the vehicle. To do so contaminates the system and can cause damage to
the system and the equipment. Damage may include compressor failure, damage to recycling
equipment, and transfer of contaminated refrigerant to other vehicles. If R12 and R134a are mixed,
the mixture cannot be readily identified. Also, increases in system pressure of as much as 25% can
occur, resulting in performance degradation and possible system damage.
Contaminated Service Equipment
Service equipment must be used with only one refrigerant. Recycling equipment, hoses, gauges,
and manifolds used for R134a systems cannot be used for servicing R12 systems. A shop that
services both R134a systems and R12 systems must have duplicate sets of equipment. The
practice of flushing a system with CFCs can no longer be continued because federal and local laws
prohibit venting of CFCs into the atmosphere.
Disposing of Contaminated Refrigerant

Page 2406

Page 4690
Specifications
Impact Sensor: Specifications
Service Specifications
Front Impact Sensor Resistance .........................................................................................................

...................................................... 2,000 ± 100 Ohms
Page 3158
Idle Speed: Testing and Inspection
1. Before inspection, set the vehicle to the following conditions:
- Engine coolant temperature: 80 - 95° C (176 - 203° F).
- Lights and all accessories: "OFF".
- Transmission: Neutral (P for A/T).
2. Check the basic ignition timing.
The standard value is 5° ± 3° BTDC.
3. After turning the ignition switch to "OFF", connect the scan tool to the data link connector. 4.
Start the engine and run it at idle. 5. Run the engine at idle for 2 minutes. 6. Check the curb idle
speed.
The standard value is 700 ± 100 RPM.
NOTE: The idle speed is adjusted automatically by the Idle Air Control (IAC) system.
7. If there is a deviation from the standard value check the MFI components.
Page 1547
Oil Pressure Gauge: Service and Repair Oil Pressure Gage, Inclinometer and Voltage Meter
Oil Pressure Gage, Inclinometer And Voltage Meter - Disassembly And Reassembly
Disassembly Steps
1. Meter garnish 2. Meter glass 3. Window plate 4. Voltage meter 5. Inclinometer 6. Oil pressure
gage 7. Connector bracket 8. Meter harness 9. Meter case
Disassembly
To disassemble follow the steps listed above.
Reassembly
To reassemble reverse the steps listed above.

Page 1146
Air Bag(s) Arming and Disarming: Service and Repair
WARNING: The manufacturer provides arming and disarming instructions as part of each
applicable service procedure.
Read and understand all applicable service procedures completely before begining work on
Supplemental Restraint System (SRS) components or when working near SRS Components or
SRS electrical circuits.
Failure to follow all SRS service precautions and procedures may result in damage to the vehicle,
personal injury or death.
Page 4993
it. Also the pole piece may not be able to sense correctly the wheel rotation speed if it is damaged.
2. Measure the resistance between the speed sensor terminals. The standard value for the front is
1,170 - 1,350 ohms and rear is 1300 - 1500 ohms.
If the internal resistance of the speed sensor is not within the standard value, replace it with a new
speed sensor.
3. Remove all connections from the speed sensor, and then measure the resistance between
terminals Nos. 1 and 2 and the body of the speed
sensor.The standard value is 100,000 ohms or more. If the speed sensor insulation resistance is
outside the standard value range, replace with a new speed sensor.
4. Check the speed sensor cable for breakage, damage or disconnection; replace with a new one if
a problem is found.
NOTE: When checking for cable damage, remove the cable clamp part from the body and then
bend and pull the cable near the clamp.
Page 2389
Spark plug ID
NGK .....................................................................................................................................................
................................................................PFR5J-11
Denso ..................................................................................................................................................
............................................................PK16PR-P11
Page 5854
1997 Mirage, Volume 1, page 52B-4, and 1997 Mirage Technical Information Manual, Page 6-13
Page 913
Page 773

Page 2667
on actual vehicles.
Wire Color Codes
Page 4116
9. Remove the primary regulator valve sleeve and primary regulator valve plunger together and
then remove the spring, washer and primary regulator
valve.
10. Remove the primary regulator valve plunger from the primary regulator valve sleeve.
11. While pushing the sleeve with a finger, use a magnet to remove the seat.
12. Remove the accumulator control valve sleeve, accumulator control valve and spring together.
13. Remove the spring and accumulator control valve from the accumulator control valve sleeve.
14. Using a magnet, remove the pin. 15. Remove the plug.
Inspection
Page 875
the standard value.

the system.
Locations
Condenser Fan Motor Relay: Locations

Page 2200
Throttle Position Sensor: Adjustments
1. Connect the scan tool to the data link connector. When not using the scan tool, proceed as
follows.
1) Disconnect the connector of the throttle position sensor. 2) Connect an ohmmeter between
terminal 2 (closed throttle position switch) and 1 (sensor ground) by using jumper wires.
2. Insert a feeler gage with a thickness of 0.65 mm (0.0256 in.) between the fixed SAS and throttle
lever. 3. When using the scan tool, turn the ignition switch ON. (but do not start the engine.)
4. Loosen the throttle position sensor mounting bolts and turn the throttle position sensor body fully
clockwise. 5. In this condition, make sure that the closed throttle position switch is ON. (There is
continuity between terminals 1 and 2.)
6. Slowly turn the throttle position sensor counter-clockwise until the point at which the idle switch
is turned off (continuity between terminals 1
and 2 changes to non-continuity) is found. Tighten the throttle position sensor installation bolt at
that position.
Page 6267

Page 6589
Grounding Markings

Page 3058
Air Injection Vacuum Control Solenoid Valve: Testing and Inspection
Reed Switch Check
1. Check that the speedometer operates correctly. 2. Start the engine. Do not disconnect the
connectors. Check the continuity between terminals (1) and (2) while moving slowly the vehicle
forward.
The continuity and discontinuity should alternate.

Page 3986
a. If loose or damaged, replace the sensor rotor. Then go to Step 5.
b. If the sensor rotor is OK, go to Step 5.
5. Using the MUT-II, erase the DTCs. Then test drive the vehicle at 40 mph for at least one minute.
a. If the transmission shifts normally and the MIL does not come on, continue with Step 6.
b. If the transmission does not shift normally and/or the MIL comes on, check for new DTCs set in
the TCM other than DTC 31 or DTC 32. Refer to the service manual for diagnosis and repair
instructions for the appropriate DTC(s).
c. If the MIL comes on or DTC 31 or DTC 32 is set, go to Step 6.
6. Replace the TCM. Refer to the PARTS INFORMATION section of this bulletin.
PARTS INFORMATION
Use standard warranty procedures. In the "Cause" section of the warranty claim, list any DTCs that
were noted in Step 1 of the PROCEDURE section of this bulletin.
Page 3398
follows.
that position.
Page 1992
HARNESS INSPECTION
NOTE: -
- 92)
control module. -
(A3 - 90, A7 - 19)

Engine - Valve Noise at Start-up
Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Valve Noise at Start-up
NO.: TSB-95-11-001
MODEL: V6 and DOHC Models
SUBJECT: VALVE NOISE AT START-UP
BACKGROUND INFORMATION On V6 and DOHC models, it is normal to hear a valve noise (a

"ticking" sound) during the first two minutes after engine start-up. However, vehicles that are
overdue for oil change or have not been started for a long period of time may experience the noise
for longer than two minutes. The noise is caused by air in the high pressure chamber inside the
automatic valve lash adjusters.
Replacing valve lash adjusters will probably not eliminate valve noise. This bulletin contains
procedures to bleed air out of the adjusters and to confirm that the adjusters do not require
replacement.
NOTE:
For Eclipse models with 420A engine, refer to the "Lash Adjuster Check" on page 110-12 in the
1996 Eclipse service manual. Do not perform the procedures in this bulletin.
VEHICLES AFFECTED All V6 and DOHC models
PROCEDURE
If valve noise (a "ticking" sound) lasts more than two minutes after engine start-up, perform the
following steps in order:
1. Check the engine oil level and quality, and correct as necessary. Start the engine. If the valve
noise continues for longer than two minutes after start-up, continue with Step 2.
2. Warm the engine to normal operating temperature. Increase idle speed gradually to 3,000 rpm,
then back down to normal idle speed. Repeat this process several times (maximum of ten times). If
the valve noise continues, stop the engine. Inspect the automatic valve lash adjusters as described
in Steps 3 and 4 below.
CAUTION:
Wear protective gloves and use care to protect yourself from hot engine components.
3. Remove the oil cap on the rocker cover and listen for the source of the noise. If it seems to be
coming from the valve lash adjusters, proceed to Step 4. Otherwise, refer to section 11 of the
appropriate service manual for further engine diagnosis to determine the cause of the noise.
4. Remove the rocker cover.
5. Using finger pressure, push down on the rocker arm over the head of each valve lash adjuster.
NOTE:
Specifications
Temperature Sensor (Gauge): Specifications
Engine coolant temperature gage unit is a Thermistor type gage unit.
Page 442

Page 3856
DISASSEMBLY
INSPECTION
Steering - Tie Rod Torque Specifications Change
Tie Rod End: Technical Service Bulletins Steering - Tie Rod Torque Specifications Change
NO.: TSB-97-37A-004 DATE: August, 1997 MODEL: See below
Subject: TIE ROD TORQUE SPECIFICATIONS SERVICE MANUAL REVISION
[TSB Revision TSB-97-37A-004]
PURPOSE The steering linkage tie rod end torque specifications have been changed for affected
models.
The new tie rod end torque specifications are:
4-wheel drive models: 80-110 Nm (58-80 ft/lbs) 2-wheel drive models: 65-75 Nm (43-54 ft/lbs.)
AFFECTED VEHICLES
1984-97 Montero 1987-96 Truck
AFFECTED SERVICE MANUALS
1984 Montero, Volume 1, pages 19-3, 19-31 1985 Montero, Volume 1, pages 19-3, 19-36 1986
Montero, Volume 1, pages 19-3, 19-38 1987 Montero, Volume 1, pages 19-4, 19-39 1988 Montero,
Volume 1, pages 19-4, 19-40 1989 Montero, Volume 1, pages 19-4, 19-37 1990-91 Montero,
Volume 1, pages 37-4, 37-39, 1992-95 Montero, Volume 1, page 37A-39, 1996 Montero, Volume 1,
page 37A-35 1997 Montero, Volume 1, page 37A-35 1987 Truck, Volume 1, pages 19-5, 19-52,
19-53 1988 Truck, Volume 1, pages 19-4, 19-55, 19-56 1989 Truck, Volume 1, pages 19-4, 19-48,
19-49 1990 Truck, Volume 1, pages 37-4, 37-39 1991 Truck, Volume 1, pages 37-4, 37-39
1992-96 Truck, Volume 1, pages 37A-4, 37A-39
Page 4031
Page 140
Page 7045
RELAY VIEW
Horn Relay C
Page 3505
on actual vehicles.
Wire Color Codes
Page 2917
Specifications
Gear Sensor/Switch: Specifications
Detection Switch ..................................................................................................................................

........................................... 35 Nm (26 ft. lbs.)
Specifications
Temperature Warning Lamp/Indicator: Specifications
Automatic Transmission oil temperature warning light
.............................................................................................................................................. 1.12 W
Page 5652
Ambient Temperature Sensor / Switch HVAC: Testing and Inspection
Outside Temperature Sensor Check
Check that the internal resistance values of the outside temperature sensor are at the standard
values when each sensor shows temperatures of 20°C (68° F) and 40°C (104°F).
Standard value: 20°C (68°F) : Approx. 1,200 Ohms 40°C (104°F) : Approx. 500 Ohms
Page 3430
Throttle Cable/Linkage: Adjustments
Accelerator Cable
1. While holding link (C) so that it is touching the stopper, adjust the play of the accelerator cable
with the adjusting nut so that the cable play is at
the standard value.
Standard value ELC-4A/T 2 - 3 mm (0.08 - 0.12 in.) Except ELC-4A/T 0 - 1 mm (0 - 0.04 in.)
2. After adjusting, secure the cable with the lock nut.
Throttle Cable
1. While holding link (B) so that it is touching link (C), adjust the play of the throttle cable with the
adjusting nut and adjusting bolts
side> so that the cable play is at the standard value.
Standard value: 1 - 2 mm (0.04 - 0.08 in.)
2. After adjusting, secure the cable with the lock nut.

Page 6035
Page 1163


Page 419

Page 6155
Exterior Moulding / Trim: By Symptom
Technical Service Bulletin # 97-42A-007 Date: 970401
Wind Noise At Upper Windshield
NO: TSB-97-42A-004 DATE: April, 1997 MODEL: 1992-97 Montero
Subject: WIND NOISE AT UPPER WINDSHIELD
PURPOSE
Some vehicles may experience a wind noise (whistle) coming from the upper area of the
windshield. The noise is due to air flow between the windshield moulding and the glass. To
eliminate the noise, secure the windshield moulding as described in this bulletin.
AFFECTED VEHICLES
1992-97 Montero
PROCEDURE
To eliminate wind noise at the upper area of the windshield:
1. Use isopropyl alcohol to clean dirt and adhesive residue from behind the outer edge of the upper
and side moulding. Use a plastic trim stick to gently lift the outer edge of the moulding.
2. Prepare the application nozzle of 3M 08661 silicone sealant or equivalent as shown:
a. Cut the tip of the applicator nozzle diagonally (approx. 250) as shown.
b. Cut a small notch at the slanted end.

Page 612
Oxygen Sensor: Mechanical Specifications
Oxygen Sensor 29-36 ft.lb

Page 6653
Oil Pressure Gage Simple Check

Page 3179
Air Flow Meter/Sensor: Oscilloscope Patterns and Waveforms
Wave Pattern Inspection Using an Analyzer Measurement method
(1) Disconnect the volume air flow sensor connector, and connect the special tool (test harness:
MB991348) in between. (All terminals should be
connected.)
(2) Connect the analyzer special patterns pickup to terminal. (3) of the volume air flow sensor
connector.
Connect the analyzer special patterns pickup to ECM terminal (90).
Standard wave pattern Observation Conditions
Observation conditions (Pattern changes with engine speed changes)
increased.
Page 1289
Be sure that the camshaft lobe is on the flat side when performing this step.
a. If the head of the adjuster sinks when finger pressure is applied, the adjuster must be replaced.
b. If the head of the adjuster stays firm when finger pressure is applied, the adjuster is operating
normally. Do not replace the adjuster. Refer to section 11 of the appropriate service manual for
further engine diagnosis to determine the cause of the noise.
Valve Lash Adjuster Inspection (All)
Nature Code: 80B Cause Code: 220
Labor Operation Number: 11321500 Time Allowance: 0.3 hrs.
Warranty Coverage: 36 months/36,000 miles if not related to owner maintenance.
Special Warranty Information:
^ Use labor operation number 11131000 for rocker cover removal and reinstallation. (0.2 hrs. per
cover, i.e., V6 = 0.4 hrs., 4 cylinder = 0.2 hrs.)
^ Perform only when due to customer complaint and after attempt to determine if due to lack of
maintenance (i.e., overdue oil changes). If due to lack of maintenance, advise customer that
condition is their responsibility. Advise customer that a ticking noise for a short time during
warm-up is normal.
Throttle Full Close Switch: Diagram Information and Instructions
Page 2800
on actual vehicles.
Wire Color Codes
Page 5791
RELAY VIEW
A/C Compressor Relay B

Oil Pressure Warning Lamp/Indicator: Diagram Information and Instructions
Page 1526
5. Place a wooden block to the oil pan, lower as shown in the figure and remove by tapping with a
hammer.
CAUTION: The use of an oil pan remover tool No. MD998727, or equivalent, can damage the
upper aluminum made oil pan.
6. Remove sealant from oil pan and cylinder block mating surfaces. Degrease the sealant coated
surface and the engine mating surface.
7. Apply Mitsubishi Genuine Part No. MD970389, or equivalent sealant, around the gasket surface
of oil pan as specified in illustration.
NOTE: The sealant should be applied in a continuous bead approximately 4 mm (0.16 inch) in
diameter.
8. Assemble oil pan to cylinder block within 30 minutes after applying the sealant. Tighten the oil
pan mounting bolt in the order illustrated to 10 -
12 Nm (7 - 9 ft. lbs.).
Page 3867
Part 3 Of 3
Page 3964


Page 698

Page 3506
Wire Color Codes
the marking color.

Rectifier Diode / Bridge: Testing and Inspection
1. Inspect the (+) heat sink by checking the continuity between the (+) heat sink and stator coil lead
wire connection terminal using a tester. If there is
a continuity at both, the diode is short circuited, so replace the rectifier.
2. Inspect the (-) heat sink by checking the continuity between the (-) heat sink and stator coil lead
wire connection terminal using a tester.
3. Check the diode trio by connecting an ohmmeter to both ends of each diode and check the
continuity of the three diodes.
Page 5882
7. Connect two wires, each six meters (20 feet) long or more, to the two leads of SRS AIR BAG
ADAPTER HARNESS A and cover the connections
with insulation tape. The other ends of the two wires should be connected to each other
(short-circuited), to prevent sudden unexpected deployment of the air bag.
8. Connect the clock spring 2-pin connector (red) to SRS air bag adapter harness A and pass the
deployment wires out of the vehicle.
Deployment Inside The Vehicle
9. Connect the SRS air bag adapter harness A to the 2-pin connector (red) of the air bag module
(front passenger's side) and pass the deployment
wire out of the vehicle.
Deployed Inside The Vehicle
10. At a location as far away from the vehicle as possible, disconnect the two connected wires from
each other, and connect them to the two terminals
of the battery (removed from the vehicle) to deploy the air bag.
CAUTION: 1. Before deploying the air bag in this manner, first check to be sure that there is no one
in or near the vehicle. Wear safety glasses, suitable ear
protection.
2. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to
allow it to cool before attempting to handle
it. Although not poisonous, do not inhale gas from air bag deployment. See Deployed Air Bag
Module Disposal Procedures for
Page 1651
Timing Belt: Testing and Inspection
Replace belt if any of the following conditions exist. 1. Hardening of back rubber-back side is glossy
without resilience and leaves no indent when pressed with fingernail.
2. Cracks on rubber backing. 3. Cracks or peeling of canvas. 4. Cracks on tooth bottom. 5. Cracks
on side of belt.
6. Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife.
7. Abnormal wear on teeth. 8. Tooth missing and canvas fiber exposed.

Page 6535
CAUTION:

Page 2976
OPERATION
Brake Switch (Cruise Control): Testing and Inspection
1. Disconnect the connector.
2. Check for continuity between the terminals of the switch.

Page 3379
CLOSED THROTTLE POSITION SWITCH CHECK
(1) With the accelerator pedal released, check that the throttle valve lever or the fixed SAS is
pushed.
NOTE: If it is not pushed, adjust the fixed SAS.

(2) Disconnect the throttle position sensor connector.
(3) Check for continuity between throttle position sensor connector terminal (1) (sensor ground)
and terminal (2) (closed throttle position switch).
NOTE: If there is no continuity when the accelerator pedal is released, loosen the throttle position
sensor installation screw; then, afier turning all the way in the clockwise direction, check again.
(4) Replace the throttle position sensor (with built-in closed throttle position switch) if there is a
malfunction.
NOTE: For the closed throttle position switch and throttle position sensor adjustment procedure,
refer to Throttle Position Sensor.
Page 3409

Page 1920

Page 6356


Page 4405

Engine Upper Oil Pan - Installation Procedure Revision
Oil Pan: Technical Service Bulletins Engine Upper Oil Pan - Installation Procedure Revision
NO.: TSB-97-11-009 DATE: May, 1997 MODEL: See Below
SUBJECT: CORRECTED UPPER OIL PAN INSTALLATION PROCEDURES - SERVICE MANUAL

REVISION
PURPOSE This bulletin corrects the upper oil pan installation procedures for 1992-97 Montero and
1992-96 Diamante shown in the 1992-96 Engine (Overhaul) Service Manual and for the 1996 and
1997 Montero in the volume 1 service manual for each of these vehicles.
AFFECTED VEHICLES 1992-96 Diamante 1992-97 Montero
AFFECTED SERVICE MANUAL 1992-96 Engine (Overhaul) Service Manual, Page 11E-138 1997
Montero Service Manual, Volume 1, Page 11B-40 1996 Montero Service Manual, Volume 1, Pages
11B-59, 11D-41

Page 3507
Specifications
Low Beam Indicator: Specifications
Upper beam indication light .................................................................................................................
...................................................................... 1.12 W
Description and Operation
Fillpipe Restrictor: Description and Operation
Fillpipe Restrictor
The fillpipe restrictor is used to prevent leaded fuel from being added to the fuel tank. The gasoline
pump for unleaded fuel has a smaller nozzle. The fillpipe restrictor will only allow the unleaded type
nozzle to be inserted into the fuel tank.
Page 3288
Fuel Tank Pressure Release Valve: Testing and Inspection
Attach a clean rubber hose, and check the operation of the fuel tank pressure relief valve.
Page 696

Locations
Ignition Control Module: Locations

Locations
COMPONENT VIEW VIEW

Page 5127
Auxiliary Power Outlet: Service and Repair For Rear Seat
Accessory Socket - Removal And Installation
Removal
To remove follow the steps listed in the image.
Installation
To install reverse the steps listed in the image.

Page 5919
Standard value: 2,000 ± 100 Ohm
CAUTION: Always replace the sensor with a new one if the resistance is not within the standard
value.
5. Check for continuity between the terminals and the brackets.
If there is continuity, the sensor insulation is defective, and so the sensor should be replaced with a
new one.
Page 4270
Control Unit: Testing and Inspection
INSPECTION
1. Measure the terminal voltages under each condition. 2. With the control unit connected to the
harness and the probe inserted into the rear of the harness connector, carry out the voltage
measurements
between terminal (6) (ground terminal) and each other terminal.

Page 1541
Oil Pressure Gauge: Description and Operation
- When the ignition key is turned to the "ON" position, the oil pressure gage is activated.
- When oil pressure is high, the internal contacts of the gage unit are kept closed for a longer
period of time. This causes more current to flow in the circuit, and the gage pointer swings to the
high pressure side.
- When oil pressure is low, the internal contacts of the gate unit open in a shorter period of time.
Therefore, there is less current flowing in the circuit, and the gage pointer swings to the low
pressure side.
Page 6500
Cigarette Lighter: Testing and Inspection Troubleshooting Hints
1. The cigarette lighter illumination light does not illuminate.
- Check the cigarette lighter.
2. The cigarette lighter illumination light does not illuminate or does not dim.
a. The tail lights illuminate.
- Check the bulb.
- Check the rheostat.
b. The tail lights also do not illuminate.
- Check the tail light relay.
- Check the column switch.
3. The ashtray illumination light does not illuminate.
a. The tail lights illuminate.
- Check the bulb.
b. The tail lights also do not illuminate.
- Refer to item 2, step (2).

Page 3918
Return Spring Assembly
1. Measure the free length of the spring including the spring seat.
Standard value: Approximately 18.6 mm (0.732 inch)
ASSEMBLY
A. Snap ring installation. (5)
CAUTION: -
Be sure the end gap of the snap ring is not aligned with the cutout of the support.
- Set the support in such a way that its central convex portion doesn't touch the workbench.
Front Axle
Differential Carrier: Service and Repair Front Axle
Oil Seal Replacement
1. Remove the under cover. 2. Remove the front hub and knuckle assembly.
3. Remove the left drive shaft.
CAUTION: When pulling the left drive shaft from the differential carrier assembly, be careful that
the drive shaft spline does not damage the oil seal.
4. Remove the right drive shaft from the inner shaft assembly. 5. After removing the shock
absorber (R.H.) lower mounting bolt, remove the inner shaft.
CAUTION: When pulling the inner shaft out from the differential carrier, be careful that the spline of
the inner shaft does not damage the oil seal.
6. Remove the actuator mounting bolt from the housing tube, and then remove the harness from
the clamp. 7. Remove the differential mounting bracket (R.H.) and housing tube.
8. Use the special tool to remove the oil seal.

Page 4109
1. Remove the bolt and then remove the detent spring and cover.
2. Remove the manual valve from the lower valve body.
3. Using a deep socket wrench [8 mm (0.31 inch)], remove the 25 bolts from the upper valve body.
4. Separate the upper valve body from the lower valve body by pushing the valve body plate and
gasket toward the upper valve body. 5. Place the upper valve body on the workbench with the side
having the gasket and plate upward.
Page 1839

Page 3478
Camshaft Position Sensor: Locations

SENSOR VIEW
Camshaft Position Sensor G

Page 2123

Page 2530
Before beginning reprogramming, you must first transfer new reprogramming data from a DVD to a
PC memory card adapter equipped with a compact flash memory chip. The data is transferred from
the DVD-ROM to the PC hard drive, then to the PC memory card.
Components
MUT-III personal computer Reprogramming database on DVD-ROM Memory card (MB991853)128

MByte Compact Flash (CF) * Memory card adapter (MB991939) PCMCIA *
* Replacement generic memory and adapters can be ordered from SPX/OTC, or purchased locally.
Procedure
1. Start the MUT-III personal computer.
2. Start the MUT-III system.
3. Install the memory card into the card adaptor.
4. Install the card adapter into the PC card slot. (There are two PC card slots. You can use either
slot for the card adapter.)
A "Found New Hardware" message displays on the monitor. Wait for the message to disappear.
5. When you receive new reprogramming data, install the reprogramming DVD-ROM into the PC's
DVD-ROM drive.
6. Select "Special function".
7. Select "ECU reprogramming".
8. If a "Please update to a new database file" message displays, press the check mark button.
9. A "Please wait!" message displays. When the transfer is complete, the message disappears.
Then remove the DVD-ROM from the PC.
10. Select "Memory card transfer". (Do not remove the memory card from the PC.)
11. Select memory card "E:\" and press the check mark button.
A/C Refrigerant - Service Information
NO.: TSB-96-55-006
DATE: May, 1996
MODEL: All with A/C
SUBJECT: A/C REFRIGERANT SERVICE INFORMATION
PURPOSE
Beginning January 1, 1996, the production of CFC (chlorofluorocarbon) refrigerants such as

R12(Freon) was prohibited in the United States as part of an international agreement to protect the
atmosphere. New HFC (hydrofluorocarbon) refrigerants such as R134a are now used in all
new-vehicle automotive air conditioning systems instead of the formerly-used R12.
This bulletin describes:
^ refrigerants and their availability,
^ differences between A/C systems, refrigerants, and lubricants,
^ retrofitting R12 systems to use R134a,
^ recovery and recycling of refrigerants,
^ storing and transferring recycled refrigerant,
^ typical causes of A/C system contamination, and
^ disposal of contaminated refrigerant.
Refrigerants and Their Availability
In 1993, auto makers began using R134a refrigerant in new-vehicle air conditioning systems. Yet in
early 1996 there are still an estimated 90-150 million vehicles in service that use R12 as a
refrigerant in their systems. Now that R12 can no longer be produced legally, the price of this
refrigerant is rising, and cheap substitutes and illegal supplies are appearing on the market.
As of this writing, there are only three EPA-approved alternatives to R12. These are R134a, R401c,
and FRIGC. These refrigerants, including R12 are not interchangeable and cannot be mixed in a
system. Because of the high cost of R134a and the rising prices of diminishing field stocks of R12,
other refrigerants, sometimes called "drop-in" refrigerants, are appearing on the market. Some of
these are mixtures that can contain impure R12 or R22 (a commercial refrigerant not used in auto
A/C systems), or mixtures of flammable hydrocarbons such as butane and propane. Impure R12
can have adverse effects on A/C systems and service equipment.
System Differences
A system that is charged with one type of refrigerant can become contaminated when serviced with
equipment that is used for other refrigerants. The system can be damaged by these contaminants;
resulting in costly repairs; and when the contaminants get into the servicing equipment they can
spread to other vehicles like a virus. To prevent this; industry standards have been developed so
that an A/C system designed for one kind of refrigerant cannot accept equipment designed for
another. Underhood labels on each vehicle clearly state the factory charge by type and amount of
refrigerant. Fittings on R12 systems are not the same as those on R134a systems. Unlike R12
systems which typically use threaded service fittings for the high and low sides; R134a systems
use quick coupler fittings without external threads. The high side has a 16 mm O.D. fitting while the
low side has a 13 mm O.D. fitting. R12 system fittings are 7/16"-20; R134a fittings have 1/2"-16
Acme threads.
Since R134a is made up of smaller molecules than R12; R134a tends to leak through hoses easier
than R12. For this reason, service hoses for the two refrigerants have different specifications.
Service hoses for R12 are marked "SAE J2196". The low-side hose is solid blue or black with a
blue stripe; the high-side hose is solid red; or black with a red stripe. The utility hose is either solid
yellow or white; or black with yellow or white stripe. Service hoses for R134a are labeled "SAE
J2196-R134a" and are color-coded as follows: solid blue with black stripe for the low-side hose,
solid red with a black stripe for the high-side hose, and solid yellow with black stripe for the utility
hose.
Refrigerant Differences
R12(Freon) and R134a are not compatible and must never be mixed. R134a is less efficient than
R12. Higher operating pressures and larger system components make up for the difference in
performance. Leakage is of greater concern with R134a because its molecules are smaller than
those of R12 and it can seep through the rubber hoses more easily. R134a mixed with
high-pressure air can be ignited under certain conditions by a spark or open flame. R134a is an
irritant and also very corrosive. It will tarnish and discolor any metal with which it comes in contact
in liquid form.
R12 is highly toxic when exposed to flame. The product of its combustion is phosgene gas, a
powerful irritant to human tissue. R12 gas released into the atmosphere rises to the stratosphere
where it can linger for decades. In the stratosphere, a layer of ozone acts as a sunscreen that
protects Earth from the sun's ultraviolet rays. The R12 reacts with the ozone to produce
compounds that cannot filter the sunlight, allowing more ultraviolet radiation to reach Earth. More
ultraviolet rays can cause increase in skin cancer, more eye cataracts, reduced immunity to
disease, damage to vegetation, and increased amounts of ozone at ground level where smog is
formed.
Page 6739
Grounding Markings

Locations
Main Relay (Computer/Fuel System): Locations

Page 549
on actual vehicles.
Wire Color Codes
Page 1604
Disassembly Steps
Disassembly
Reassembly

Page 4550
Output Shaft: Service and Repair Rear Output Shaft
DISASSEMBLY
A. Ball bearing removal. (2)
ASSEMBLY
A. Ball bearing installation. (2)

Page 138
Page 1186


NO.: TSB-95-16-003
MODEL: All Models
VEHICLES AFFECTED
All models
PROCEDURE
CAUTION:

Page 4826

Page 5555
CONTROL UNIT VIEW
Variable Shock Absorber Control Unit I
Page 7068
Wire Color Codes
the marking color.

Interior - Wind Noise Diagnosis
Weatherstrip: Technical Service Bulletins Interior - Wind Noise Diagnosis
NO.: TSB-97-42A-001 DATE: February, 1997 MODEL: All Models
SUBJECT: WIND NOISE DIAGNOSIS
PURPOSE As vehicle interiors become quieter, wind noise becomes more noticeable to the
customer. Modern sealing techniques and smooth aerodynamic exteriors significantly reduce the
causes of wind noise. Customer expectations of interior quietness require technicians to detect and
correct even small wind noises. This bulletin describes common causes of wind noise and how to
diagnose them.
Specific corrective actions may vary from model to model.
AFFECTED VEHICLES All Mitsubishi models
CAUSES OF WIND NOISE Wind noise may be created by:
^ Air turbulence as air flows over the vehicle
^ Aspiration as air enters or leaves the interior
^ Vibration of a vehicle part from force of air flowing over it
Air Turbulence When air flows smoothly over a moving object, no noise is produced. If the smooth
flow of air is disturbed by an edge, gap or projection, the air flow becomes turbulent and creates
wind noise.
Aspiration When a pressure difference exists between two spaces (such as between a vehicle's
interior and exterior), any opening will allow air to move from a high pressure space to a lower
pressure space. As the air flows from one space to another, aspiration noise is created. Common
causes of aspiration noise are loose weatherstripping and partially open sunroof, doors or
windows. Aspiration noise varies with vehicle speed and ventilation blower speed.
Vibration Wind noise can also be caused by air flowing over a vehicle part and causing it to vibrate.
Vibrating air intake grilles made of thin bars, radio antennas, outside mirrors, and loose or
protruding body mouldings are common causes of wind noise.
DIAGNOSIS PROCEDURES
1. Ask the customer for details about the apparent location of the noise and the conditions under
which the noise occurs. Try to determine the vehicle speed, weather conditions, and wind direction.
2. Test drive the vehicle under similar conditions with the customer. The technician should sit in the
appropriate seat where the wind noise is most audible.
3. A stethoscope, ultrasonic leak detector or smoke generator can assist in detecting the source of
an aspiration type of wind noise. A smoke generator and ultrasonic leak detector can be used when
the vehicle is not moving.
NOTE:
Leak detectors and smoke generators cannot identity wind noise created by vibrating mouldings,
air intake grilles or antennas. Diagnose this type of noise during test drives.
a. Leak detectors have a sound wave emitter and a receiver. Hold the emitter inside the vehicle
with the doors closed. Sound waves from the emitter are picked up by a receiver being held outside
the vehicle. Any gap in the vehicle's sealing provides a path for the sound waves to travel through.
b. With the heater/air conditioning blower on the highest setting with the outside air circulating, hold
a smoke generator outside the vehicle near a suspected air leakage area. Visible air flow inside the
vehicle will reveal where air leaks exist. Good light and calm air are important when using this
method.
4. Determine whether any accessories or other easily removed parts could cause wind noise by
vibrating as air flows over them. Antennas and roof
Page 3493
increased.

Locations
COMPONENT VIEW VIEW

Page 4949
RELAY VIEW
ABS Relay Box (with built-in A
motor relay and valve relay)

Page 312
speed sensor.
a problem is found.
Service and Repair
Page 5544
NOTE:
If differential replacement is necessary, refer to the proper parts catalog for the vehicle being
serviced for part number information.
Service and Repair
Power Steering Line/Hose: Service and Repair
REMOVAL
1. Drain power steering fluid. 2. Follow removal steps outlined in illustration.
INSTALLATION
NOTE: Installation service points as follows: a. Pressure pipe/pressure hose installation (2 & 4).
1. Install so that the pressure pipe and pressure hose mating marks are aligned.
Page 5474
1998 Montero Service Manual, Volume 2, Page 37A-8 Add the new steering angle adjustment
caution statement as shown.
Page 6675
Outside Temperature Display Sensor: Description and Operation
- When the ignition switch is turned to the "ON" position, the DC signal output from the inside
temperature sensor and outside temperature sensor is converted from an analog signal to a digital
signal by the A/D conversion circuit inside multi-meter.
- This digital signal is evaluated by the calculating circuit in the CPU and the resulting value is
displayed on the digital display.
Page 718

Page 6732
Fuel Gauge Sender: Mechanical Specifications
Fuel Gage Unit Check
A (Float point "F") ................................................................................................................................

........................................................ 119.3 (4.69) in. B (Float point "E") ..............................................
........................................................................................................................................ 255.0
(10.03) in.
Specifications
Throttle Cable/Linkage: Specifications Free Play
Free Play
With ELC4-A/T 2 - 3 mm
Except ELC4-A/T 0 - 1 mm
Throttle Cable 1 - 2 mm
SRS - Diagnostic Trouble Code (DTC) Erasure
Air Bag Control Module: Technical Service Bulletins SRS - Diagnostic Trouble Code (DTC) Erasure
No.: TSB-95-52B-002
MODEL: All models with SRS
DIAGNOSTIC TROUBLE CODE (DTC) ERASURE
VEHICLES AFFECTED All models equipped with Supplemental Restraint System (SRS)
DTCs set in the SRS diagnosis unit remain in memory until they are erased with the MUT-II scan
tool. It is important for all SRS DTCs to be erased after troubleshooting and repairs. In the event of
an accident involving air bag deployment, only the DTCs pertaining to the accident should be in the
SRS diagnosis unit memory.
Disconnecting the battery cables will not erase SRS DTCs.

After completing SRS troubleshooting and repairs as described in section 52B of the appropriate
service manual, erase all SRS DTCs with the MUT-II scan tool.
Use standard warranty procedures. Diagnosis time is included in component replacement time in
the MMSA Labor Operation Time Schedule.
Page 2594
on actual vehicles.
Wire Color Codes
Page 715
SENSOR VIEW
Vehicle Speed Sensor W

Page 6624
Maintenance Required Lamp/Indicator: Electrical Diagrams

Specifications
Camshaft Position Sensor: Specifications Sensor Bolt
Sensor Bolt
Torque 7 ft.lb
Page 6075
Locations
Fuel Tank Pressure Sensor: Locations

Page 252
on actual vehicles.
Wire Color Codes
Page 1304
c. If the feeler gauge leaf cannot be inserted easily, the lash adjuster is good. Investigate other
causes for the abnormal noise.
5. Slowly turn the crankshaft 360 degrees clockwise.
6. Follow the same procedure as in Step 4 to check the rocker arms indicated by the black arrows
in the illustrations.
Bleeding Air From The Lash Adjuster System
NOTE ^
Parking the vehicle on a grade for a long time may decrease the amount of oil in the lash adjuster,
causing air to enter the high pressure chamber when starting the engine
^ After parking for many hours, oil may run out from the oil passage and take time before oil is
supplied to the lash adjuster, causing air to enter the high pressure chamber.
^ In the above cases, abnormal noise can be eliminated by bleeding the air from the lash adjuster
system.
1. Check the engine oil and add or change as necessary.

Dimmer Switch: Diagram Information and Instructions
Page 139
Page 4899
Load Compensator: Testing and Inspection Spring Length Check
LOAD SENSING SPRING LENGTH CHECK
1. Park the vehicle on a level ground. The vehicle should be unloaded and supported only by
wheels.
NOTE: Never support the vehicle with jacks or other similar means.
2. With the lever pressed all the way to the load-sensing proportioning valve side, check whether
the length of the spring (the length between its
ends) shown in the illustration is at the standard value. The standard value is 224-228 mm (8.8-9.0
inch).
3. If the spring length is not within the standard value, loosen the bolt attaching the support and
adjust the distance moving the support.
Page 2669
Page 3369

Page 1938
RELAY VIEW
Engine Control Relay F

Page 5761
When it becomes necessary to dispose of contaminated refrigerant, the refrigerant should be
stored in a suitable container as described in this bulletin, labeled to identify it clearly, and offered
to a company equipped to handle the container and the contaminated refrigerant. Your dealership
may already have a company to handle its toxic wastes, and perhaps this company can handle the
refrigerant. If a company specializing in refrigerant reclaim is preferred, the EPA Hotline
(1-800-296-1996) can provide a list of approved refrigerant reclaimers.
Page 3004

Page 1577
Intake Manifold: Testing and Inspection
Check the following points; replace the part if a problem is found.
1. Damage or cracking of any part. 2. Clogging of the negative pressure (vacuum) outlet port, or
clogging of the water or gas passages.
License Plate Lamp: Diagram Information and Instructions
Page 649


Page 4705
1998 Montero, Volume 1, page 23A-17.
Page 551
Page 3030
Wire Color Codes
the marking color.

Page 1089
Fluid - Transfer Case: Fluid Type Specifications
SPECIFIED LUBRICANTS Transfer Oil: Hypoid Gear Oil SAE 75W-85W Conforming to API
Classification GL-4
Page 6394
racks are common accessories that may cause wind noise. If possible, test drive the vehicle again
with the suspected accessory removed.
5. Note any non-factory sunroofs, roof racks and lights in the suspected wind noise area. Service
manuals do not describe repair or adjustment of these items, and they are not covered by the
Mitsubishi warranty. You may refer the customer to the aftermarket manufacturer.
6. On models with a sunroof, ensure that the sunroof is properly adjusted and closes securely.
7. On convertible models, ensure that the top is properly adjusted. The windshield header should
not leak air into the interior. Side windows should seal securely against the top weatherstripping.
8. Apply removable tape over suspected interior and exterior areas. Then test drive the vehicle to
determine whether the wind noise is eliminated.
If the noise is eliminated with the tape applied, remove the tape from one area at a time, test
driving each time you remove the tape from a suspected area. By process of elimination, you can
pinpoint the noise source.
COMMON WIND NOISE AREAS
1. Doors
a. Examine the weatherstrip for damage, deterioration, and improper installation. Rub some chalk
on the weatherstrip, then close the door. When you open the door, a break in the chalk line on the
door frame indicates an air leakage area. Repair or replace the weatherstrip.
b. Examine the door itself for misalignment or deformation. Adjust or replace as required.
2. Door Mirrors. If a door mirror is a suspected source of wind noise, disassemble the mirror.
Examine it carefully for possible damage (e.g., cracks) that might create air leakage. Repair or
replace as required.
3. Windows. Ensure that windows are properly aligned in their channels and the glass runs are
sealed securely against the glass when the door is closed.
4. Body Weatherstripping Body weatherstripping usually provides multiple barriers against leakage.
A-Pillar weatherstripping has inner and outer seals in channels or pressed against body flanges.
Where the door meets the center pillar, balloon sections compress when the door is closed. Lip
sections support balloon sections and provide additional protection against leakage. Be sure the
doors fit evenly with no gaps. Check for crushed balloon sections and weatherstripping out of its
channel. Adjust or replace as needed.
Page 1255
Component Locations

Page 2219
Page 900


Page 6656
Disassembly Steps
Disassembly
Reassembly

Page 4892
8. If a different result is obtained when checking, correct it by following the procedure in the
illustration.
HU (MOTOR) OPERATIONAL CHECK
Connect the battery and check that the sound of the hydraulic unit (motor) can be heard operating.
Caution: The battery power should not be applied for more than 1 second.
Page 3341
RELAY VIEW

Page 3171
on actual vehicles.
Wire Color Codes
Specifications
Firing Order: Specifications
Firing Order .........................................................................................................................................

............................................................. 1-2-3-4-5-6.
NOTE: This engine is a six-cylinder engine. The cylinder numbers are assigned as 1-3-5 for the
right bank and 2-4-6 for the left bank from the front of the engine (timing belt side). This engine is
fired in the order of 1-2-3-4-5-6 cylinders.
Page 4778
Wheel Speed Sensor: Mechanical Specifications
Clearance 0.008-0.039 in
Locations
Headlamp Washer Motor Relay: Locations

Page 4181
8. Change the side bearing adjusting spacers as shown in the illustration, and then adjust the final
drive gear backlash between the drive gear
and the drive pinion.
NOTE: When increasing the number of side bearing adjusting spacers, use the same number for
each side, and use as few spacers as possible.
9. Check the tooth contact of the drive gear and drive pinion. If poor contact is evident, carry out
adjustment.
10. Measure the drive gear runout at the shoulder on the reverse side of the drive gear.
Limit: 0.05 mm (0.0020 inch)
11. If the drive gear runout exceeds the limit, remove the differential case and the drive gears,
move them to different positions and then
reinstall them.
Page 492

Page 6908

Page 382
Coolant Temperature Sensor / Switch HVAC: Testing and Inspection
AIR CONDITIONING ENGINE COOLANT TEMPERATURE SWITCH
1. Dip the air conditioning engine coolant temperature switch in oil and heat the oil with a gas
burner or similar item. 2. When the oil temperature reaches the standard value, check that there is
no continuity between the switch terminals.
Standard value: 112 - 118° C (234 - 244° F)

Page 2305
on actual vehicles.
Wire Color Codes
Lower Valve Body
Upper
Ball Joint: Testing and Inspection Upper
BALL JOINT BREAKAWAY TORQUE CHECK
1. After shaking the ball joint stud several times, install the nut to the stud and use the special tool
to measure the breakaway torque of the ball joint.
Standard value: 0.8-3.5 Nm (7-30 inch lbs.)
2. When the measured value exceeds the standard value, replace the ball joint. 3. When the
measured value is lower than the standard value, check that the ball joint turns smoothly without
excessive play. If so, it is possible to
use that ball joint.

Page 5144

Page 4122
9. Remove the plug, second coast modulator valve and spring.
10. Using a magnet, remove the seat.
11. Remove the lockup relay valve sleeve, lockup relay plunger, spring and lockup relay valve
together. 12. Remove the lockup relay valve, spring and lockup relay valve plunger from the lockup
relay valve sleeve.
14. Remove the plug, second regulator valve and spring.

Page 3076
on actual vehicles.
Wire Color Codes
Page 1176
Relay Box: Application and ID
Dedicated Fuse
Page 6916

Page 4784
speed sensor.
a problem is found.
Specifications
IDLE SPEED
700 RPM Man & Auto

Page 2334
Crankshaft Position Sensor: Service and Repair
Crankshaft Position Sensor And Camshaft Position Sensor - Removal And Installation
Pre-removal and Post-Installation Operations
- Timing Belt Cover Removal and Installation
Removal
To remove follow the steps listed in the image
Installation
Locations
Page 2840
Wire Color Codes
the marking color.

Page 2145
(A4 - 79, B4 - 76, C4 - 73, D4 - 75)
(A3 - 42, 63 - 34, C3 - 43, D3 - 35)
D2 - 92)

Alignment - Two Wheel Vs. Four Wheel
Alignment: Technical Service Bulletins Alignment - Two Wheel Vs. Four Wheel
No: TT-127-00-001 DATE: June, 2006 MODEL See Below
SUBJECT: TWO WHEEL ALIGNMENT VERSUS FOUR WHEEL ALIGNMENT
Two Wheel Alignment versus Four Wheel Alignment - All models. When performing a two wheel
alignment, the steering and suspension components are adjusted to the vehicle centerline. We
then assume everything behind the front wheels is OK. However, bushings can wear, springs can
sag, collision damage and shifting of the subframe can all affect rear wheel alignment angles.
However, when performing a four wheel alignment, the angles in the rear are also measured and
taken into account.
On vehicles where adjustments are not possible (currently just the Raider) the thrust angle is
determined and the front wheels are aligned to it.
On vehicles where adjustments are possible (all current models except for Raider), the rear wheels
are first individually adjusted to the proper angles from the centerline. Then, the the front wheels
are adjusted to the proper angles from the centerline. After all adjustments have been made, the
vehicle will handle and track properly.
Page 2328
OPERATION
Page 2351
NOTE:
Page 1852
Engine Coolant Temperature Gage Simple Check

Page 534
Specifications
Load Compensator: Specifications
DIMENSIONS
Standard Spring Length

...........................................................................................................................................................
224-228 mm (8.8-9.0 inch)
Page 6517
Clock: Description and Operation
Type .....................................................................................................................................................
...................................................... Crystal Oscillator Display method .................................................
........................................................................................................................... Fluorescent digital
display Standard error (seconds/day) ..................................................................................................
........................................................................................... ±2
Page 548


Page 1363
7. Apply Mitsubishi Genuine Part No. MD970389, or equivalent sealant, to the oil seal case area
shown in the illustration. 8. Apply a small amount of engine oil to the entire circumference of the oil
seal lip section, and place the oil seal on the cylinder block.
Page 1672
NOTE:
Page 2926
Throttle Position Sensor: Mechanical Specifications Sensor Resistance/Torque/Type/Voltage
Sensor Resistance/Torque/Type/Voltage
Between Terminals 1 And 4 3.5 - 6.5 K ohms
Torque 1.5 ft.lb
Design Variable Resister
Adjusting Voltage 400 - 1000 mV

Page 5146

Page 2216


Page 1927
Page 4254
Fluid - Differential: Testing and Inspection Rear Axle
1. Remove the filler plug and check the oil level. 2. Check that the gear oil level is not 8 mm (.3 in.)
below the bottom of the filler plug hole.
Specified gear oil:
Conventional differential, Differential with rear differential lock: Hypoid gear oil API classification G
L-5 or higher SAE viscosity 80W.
Quantity: 3.2 dm3 (3.3 qts.)
Limited slip differential: Hypoid gear oil MITSUBISHI Genuine Gear Oil or equivalent.

Page 2194
on actual vehicles.
Wire Color Codes
Page 1610

Page 2551
on actual vehicles.
Wire Color Codes
Page 3537
STEP 5. Check for continuity in the ground circuit of the ignition power transistor. -
Ignition power transistor connector: Disconnected OK: GO TO STEP 6 NG: Repair the harnesses.
(D4 - Ground)
STEP 6. Measure the ignition power transistor control signal voltage. -
Ignition power transistor connector: Disconnected
- Ignition switch: START Voltage (V): 0.5 - 4.0 OK: STOP NG: Repair the harnesses. (D1 - 11, D2 -
23, D3 - 10)
Page 260
RELAY VIEW
Defogger Timer J
Federal
Oxygen Sensor: Description and Operation Federal
OPERATION
- The heated oxygen sensor functions to detect the concentration of oxygen in the exhaust gas; it
converts those data to voltage, and in puts the resulting signals to the engine control module.
- If the air/fuel mixture ratio is richer than the theoretical air/fuel mixture ratio (i.e., if the
concentration of oxygen in the exhaust gas is low), a voltage of approximately 1 V is output; if the
air/fuel mixture ratio in leaner than the theoretical air/fuel mixture ratio (i.e., if the concentration is
dense), a voltage of approximately 0 V is output.
- The engine control module, based upon those signals, regulates the amount of fuel injection so
that the air/fuel mixture ratio becomes the theoretical air/fuel mixture ratio.
- Battery positive voltage is supplied, by way of the MFI relay, to the heated oxygen sensor heater.
As a result, the sensor element is heated by the heater, so that the heated oxygen sensor shows
excellent response even if the temperature of the exhaust gas is low.
Page 6226
Page 2111
Grounding Markings

Recall 00V311000: Possible Loss of Power Steering
Harmonic Balancer - Crankshaft Pulley: Recalls Recall 00V311000: Possible Loss of Power
Steering
Mirage model vehicles equipped with 1.5L engines; Montero Sport models equipped with 3.0L
engines; and Montero models equipped with 3.0L engines. The bolt securing the crankshaft pulley
can become loose and the pulley could fall off the vehicle.
The condition can result in a loss of power steering assist, increasing the risk of a crash.
On the Mirage vehicles, the dealers will install a new, improved crankshaft pulley bolt on the older
engines. On new engines which already have the improved bolt, the dealer will tighten the
crankshaft pulley bolt to the correct torque specification. On the Montero models, dealers will
tighten the crankshaft pulley bolt to the correct torque specifications. If the bolt is damaged, it will
be replaced.
Owner notification will be performed in five separate owner mailings, with the first mailing beginning
October 31, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon
service date and do not receive the free remedy within a reasonable time should contact Mitsubishi
at 1-800-222-0037. Also contact the National Highway Traffic Safety Administration's Auto Safety
Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Page 3582
increased.

Page 491
Grounding Markings

Intermittent Wiper Relay
Wiper Relay: Locations Intermittent Wiper Relay

Specifications
Control Module: Specifications
4WD Indication Light ...........................................................................................................................
.................................................................... 1.12 W
Page 663


Page 6286
3) Follow the repair with a fine polish and a fine polishing pad to restore luster and gloss and to
remove any swirl marks which may remain on the surface.
4) Spray an alcohol solution (50% water/50% alcohol) on the affected area. This will remove any
polish so you can be sure the damage is really repaired, not covered over.
5) Repeat step 3.
Major Damage Repair
1) Measure paint thickness with a mii gauge and record the measurements on a sheet of paper.
These measurements will help you to track the amount of paint removed.
2) To wet sand the damaged area, soak a # 2000 grit wet sandpaper in soapy water for a minimum
of fifteen (15) minutes.
3) Use a soft foam rubber sanding pad with the sandpaper to evenly distribute the sanding force.
Always sand in one direction. Frequently apply clean water to your work area to flush away
particles and prevent clogging of the paper.
4) Re-measure the paint surface. REMEMBER, do not remove more than 0.5 mil (.0005") of
topcoat.
5) To remove the sanding scratches, buff the area using a medium cutting pad and a medium-cut
cleaner.
6) Follow the repair with a fine polish and polishing pad to restore luster and gloss and to remove
swirl marks which may remain.
7) Spray an alcohol solution (50% water/50% alcohol) on the affected area. This will remove any
polish so you can be sure the damage is really repaired, not covered over.
8) Repeat step 6.
Rail Dust Repair
1) Use an Industrial Fallout Remover to remove the iron particles.
WARNING:
Use only as directed by the manufacturer. Carefully read all warnings and instructions. When
working with an Industrial Fallout Remover (acid wash), you will need protective gear (rubber
gloves and goggles).
2) Mix the solution in a large bucket to the proper specifications recommended by the Industrial
Fallout Remover manufacturer.
3) Soak large cotton towels in the solution. Apply the soaked towels on the vehicle. Do one section
at a time (i.e. hood, roof, etc.).
4) Allow the towels to remain on the vehicle for the amount of time recommended by the
manufacturer of the product. Remember, keep the towels wet with water. Do not allow the solution
to dry on the vehicle.
5) Next, rinse the vehicle with water and inspect the area. Repeat the application, if necessary.
When rinsing, use a baking soda and water solution to neutralize the acid (4 tablespoons to the
gallon). Flush the surface with plenty of water.
6) After the iron particles have been dissolved by the acid wash, any remaining pits caused by the
rail dust can be removed by following the repair steps under Minor or Major Damage Repair.
Inventory Care
Inventory care begins with frequent washing to help minimize the potential for acid rain or hard
water spotting damage. After a rain, wash every vehicle with deionized water to remove any
pollutants before they have a chance to attack the paint. Dry thoroughly because moisture
combined with pollution can also damage the vehicle's paint finish. Also, keep the vehicles a fair
distance apart on the lot to minimize dings and scratches.
Warranty Information
The paint damage outlined in this bulletin is normally classified as transportation damage and is
therefore not submitted with a warranty claim. To ensure payment for services performed, it is
essential to thoroughly inspect new vehicles upon arrival and note any paint damage on the
delivery receipt.
Page 6346
1998 Montero Service Manual, Volume 2, Page 90-139 Add connector 1 as shown and replace the
crossed-out circuit diagram on the next page of this bulletin:
Page 4700
Page 1492
Engine Oil: Technical Service Bulletins Engine - Oil Recommendations/Obsolete Oils
No: TSB-05-12-001 DATE: January, 2005 MODEL: All Models
SUBJECT: OBSOLETE ENGINE OILS
PURPOSE
Mitsubishi recommends using only engine oils that meet or exceed the ILSAC GF-3 certification by
the American Petroleum Institute (API). Oils displaying this mark meet the current engine protection
standard and fuel economy requirements of the International Lubricant Standardization and
Approval Committee (ILSAC), which is a joint effort of U.S. and Japanese automobile
manufacturers. If this mark is not on the oil, be sure that the API service symbol on the oil meets
the appropriate service classification, as explained below.
The API rates the performance level of engine oils. After analyzing an oil in laboratory engines, the
API determines the oil's overall ability to lubricate, its resistance to wear, oxidation, corrosion, and
deposit formation.
API's Service Symbol on the oil container identifies the quality of the oil. Oils for gasoline engines
have API service classifications that begin with "S" (for service), followed by a letter to indicate the
performance level of the oil.
Only three API service classifications of engine oil are acceptable: SM, SL or SJ.
API's recommendations:
^ The latest engine oil service classification (as of November 30, 2004) is SM, for all automotive
engines currently in use. SM oils are designed to provide improved oxidation resistance, deposit
and wear protection, and better low-temperature performance over the life of the oil. Oils with SM
classification are most highly recommended for all model years, to prevent sludging.
^ SL (or SL/CF) oils are recommended for 2004 and older automotive engines.
^ SJ oils are recommended for 2001 and older automotive engines.
CAUTION
Engine oils with service classification of SH, SG, SF, SE, SD, SC, SB, or SA are obsolete oils that
should not be used. These oils may cause sludging, unsatisfactory engine performance, and may
damage engine components.
Authorized Mitsubishi dealers must use the proper oil classification during servicing. Recommend
customers to always be sure that their engine oil has a service classification of SM, SL or SJ,
depending on the vehicle's model year. If a non-authorized service facility is used, advise the
customer to confirm the engine oil classification with the service facility.
Page 1836
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
OPERATION
- The engine coolant temperature sensor functions to convert the barometric pressure to voltage,
and to input that voltage (as signals) to the engine control module. The engine control module,
based upon those signals, regulates the amount of fuel injection and the fast-idling speed when the
engine is cold.
- The 5 V power supply within the engine control module is supplied, by way of the resistance
within the unit, to the engine coolant temperature sensor; it passes through the engine coolant
temperature sensor, which is a type of resistor, and is grounded at the engine control module. Note
that the resistance of the engine coolant temperature sensor decreases when the temperature of
the engine coolant increases.
- The engine coolant temperature sensor terminal voltage becomes higher when the resistance of
the engine coolant temperature sensor increases, and becomes lower when the resistance
decreases. Consequently, the engine coolant temperature sensor terminal voltage varies in
accordance with the temperature of the engine coolant, becoming lower when the temperature of
Page 6820
Wire Color Codes
the marking color.

Page 578
Fuel Tank Pressure Sensor: Testing and Inspection Harness Inspection
INSPECTION
Using Scan Tool
- The fuel tank differential pressure sensor output voltage is proportioned to the fuel tank pressure
and sent to the engine control module.
HARNESS INSPECTION
STEP 1. Check for continuity of the ground circuit -
Fuel tank differential pressure sensor connector: Disconnected OK: GO TO STEP 2 NG: Repair the
harness (A2 - 92)
STEP 2. Check for open-circuit, or short-circuit to ground between the engine control module and
the manifold absolute pressure sensor. -
Fuel tank differential pressure sensor connector: Disconnected
- Engine control module connector: Disconnected OK: GO TO STEP 3 NG: Repair the harness (A1
- 77)
STEP 3. Measure the sensor impressed voltage to the manifold absolute pressure sensor. -
- Ignition switch: ON Voltage (V): 4.8 - 5.2 V OK: STOP NG: Replace the engine control module.
Page 2497


Page 3260
Page 3970
STEP 3. Measure the park/neutral position switch terminal Input voltage. -

Engine control module connector: Connected
- Park/neutral position switch connector: Disconnected
control module.
For Cruise Control System
1. Disconnect the connector. 2. Check to be sure that there is continuity between connector
terminals (5) and (6) when the selector lever is moved to the "N range.
Page 3308
Examples of abnormal wave patterns Cause of problem Malfunction of motor (Motor is not
operating)
Induced voltage from the motor turning does not appear.

Page 3485
on actual vehicles.
Wire Color Codes
Power Steering Pressure Switch: Diagram Information and Instructions
Page 2127

Initial Inspection and Diagnostic Overview
Cruise Control Switch: Initial Inspection and Diagnostic Overview
Power Switch Inspection
1. Operate the main switch and check the continuity between the terminals.
2. Connect the positive battery terminal to terminal (5) and the negative battery terminal to terminal
(4), and then check that there is battery positive
voltage between terminal (1) and the ground when the main switch is turned to ON and during the
period before it is turned to OFF. Check that the battery positive voltage between terminal (1) and
the ground is reduced to 0 V when the main switch is turned to OFF.
Control Switch Inspection

Page 918
Page 6857
Brake Light Switch: Electrical Diagrams

Page 118
3. A progress monitor displays during data transfer to the VCI internal memory.
4. When data transfer is complete, ECU reprogramming automatically begins.
5. The ECU part number and ROM ID are displayed. Press ENTER to continue with
reprogramming.
6. If the database you selected does not apply to the vehicle's PCM, this message will display.
Press ENTER to return to the VCI main menu. Confirm PCM part number and appropriate
reprogramming database number.
Seat Belt Reminder Lamp: Diagram Information and Instructions
Page 391

Specifications
Cruise Control Servo Cable: Specifications Free Play
Free Play
Cable Deflection 1 - 2 mm
Page 1590
Grounding Markings

Interior - Floor Mat Selection/Installation Precautions
Carpet: All Technical Service Bulletins Interior - Floor Mat Selection/Installation Precautions
No: TSB-11-00-001
DATE: February, 2011
MODEL: All models & years
SUBJECT: FLOOR MAT SELECTION AND INSTALLATION
AFFECTED VEHICLES All Mitsubishi models and model years
PURPOSE
All dealership personnel should be aware of the importance of proper floor mat selection and
installation. Installing the wrong floor mats or installing floor mats incorrectly can interfere with
vehicle acceleration and/or braking potentially resulting in an accident. Follow the instructions in
this bulletin to prevent pedal entrapment and/or pedal interference.
1. Always select a floor mat that is specifically designed to fit the vehicle. Genuine Mitsubishi floor
mats are designed for each model vehicle to assure proper fit with features to assure they will
remain in place.
2. Do not install any floor mat that cannot be retained with a retaining clip, and always position and
secure the floor mat with the retaining clip. All Genuine Mitsubishi floor mats accommodate the
retaining clips in the vehicle for which they are designed.
3. Never install more than one floor mat at a time in the driver's position. Before installing a new
floor mat in the drivers position always remove the existing floor mat. Failure to remove the existing
floor mat before installing a new mat decreases the clearance between the mat and the pedals
potentially resulting in pedal entrapment and/or pedal interference. Even if the new floor mat can be
retained with a retaining clip do not install it over an existing mat.
4. After installing floor mats always verify proper operation of the accelerator, brake and clutch
pedals.
Be sure that there is sufficient clearance between the pedals and floor mat for normal pedal
operation to prevent pedal entrapment and/or pedal interference.
Terminal Resistance & Continuity Check
Electronic Brake Control Module: Testing and Inspection Terminal Resistance & Continuity Check
(Part 1 Of 2)
(Part 2 Of 2)
1. Turn the ignition switch "OFF" and disconnect the ABS-ECU connector before measuring
resistance and checking continuity. 2. Measure resistance and check continuity between the
terminals indicated in the tables. 3. The terminal layouts are shown in the illustrations.
Page 2496

Barometric Pressure Sensor: Diagram Information and Instructions
Heated Glass Element Switch: Testing and Inspection
1. Remove the rear window defogger switch from the meter bezel.
Defogger Switch - Chart
2. Operate the switch and check for continuity between the terminals.
Page 321
Component View
Engine Coolant Temperature Switch E
Page 3268


Page 2068
increased.

Control Module: Diagram Information and Instructions
Page 5016

Seat Belt Reminder Buzzer: Diagram Information and Instructions
Page 3069
Canister Purge Solenoid: Locations
Solenoid, Solenoid Valve Location Overviews
Solenoid, Solenoid Valve Location Views C - G
COMPONENT VIEW
Evaporative Emission Purge D
Solenoid
Page 2166
the standard value.

the system.
Specifications
Backup Lamp: Specifications
Back-up light ........................................................................................................................................
............................................................. 32 (1156) cp
Page 2238
- Vehicle speed sensor connector: Disconnected
Vehicle Speed Sensor Check
SENSOR CHECK
1. Remove the vehicle speed sensor and connect a 3 - 10 K Ohm resistance as shown in the
illustration at left. 2. Turn the shaft of the vehicle speed sensor and check that there is voltage
between terminal (2) and terminal (3). (1 turn = 4 pulses)
Page 532
on actual vehicles.
Wire Color Codes
Page 2992
INSPECTION
Using Scan Tool
HARNESS INSPECTION
STEP 1. Check for an open or short-circuit between the closed throttle position switch and the
- Throttle position sensor connector: Disconnected OK: GO TO STEP 2 NG: Repair the harness.
(A2 - 87)
Throttle position sensor connector: Disconnected OK: GO TO STEP 3 NG: Repair the harness. (A1
- 92)
STEP 3. Measure the power supply voltage of the closed throttle position switch. -
Throttle position sensor connector: Disconnected
- Ignition switch: ON Voltage (V): 4 or higher OK: STOP NG: Replace the engine control module.
Page 4214
Differential Case: Service and Repair Vehicles Without Limited Slip Differential
DISASSEMBLY
A. Screw removal. (1)
1. Evenly loosen 4 screws on case A and B to remove.

Input Speed Sensor
Transmission Speed Sensor: Testing and Inspection Input Speed Sensor
INSPECTION
1. Disconnect the input shaft speed sensor connector. 2. Measure the resistance between
terminals No. 9 - 10 of the sensor-side connector.
Service and Repair
Repairs and Inspections Required After a Collision: Service and Repair
WHEN AIR BAG DEPLOYS IN A COLLISION
1. Replace the following parts with new ones.
- Front impact sensors.
- SRS air bag control unit (SRS-ECU).
- Air bag modules.
2. Check the following parts and replace are any malfunctions.
- Clock spring.
- Steering wheel, steering column and intermediate joint. 1. Check wiring harness (built into
steering wheel) and connectors for damage, and terminals for deformation. 2. Install air bag
module to check fit or alignment with steering wheel. 3. Check steering wheel for noise, binds or
difficult operation and excessive free play.
3. Check harnesses for binding, connectors for damage, poor connections, and terminals for
deformities. (Refer to P.52B-8.)
WHEN AIR BAG DOES NOT DEPLOY IN LOW-SPEED COLLISION
Check the SRS components. If the SRS components are showing any visible damage such as
dents, cracks, or deformation, replace them with new ones. Concerning parts removed for
inspection, replacement with new parts and cautionary points for working, refer to appropriate
COMPONENT SERVICE.
Front Impact Sensors
1. Check radiator support panel for deformities or rust.
2. Check front impact sensor for dents, cracks deformities or rust. 3. Check sensor harnesses for
binds, connectors for damage, and terminals for deformities.
SRS Air Bag Control Unit (SRS-ECU)
1. Check SRS-ECU case and brackets for dents, cracks or deformities. 2. Check connector for
damage, and terminals for deformities.
Air Bag Module

Page 6280
I. 1997 Exterior Color Codes and Applications.
Page 5170
Centralized Relay
Page 2056

Page 4127
23. Install the spring and collar to the throttle valve cam.
24. Install the throttle valve cam to the valve body and check that the spring is anchored to the
valve body by the claw. 25. Tighten the bolt together with the washer.
26. Check that the one pin, four seats, three keys and one vibrating stopper are installed as
illustrated.
Page 2659
Power Steering Pressure Switch: Locations

Page 4033
A. Seal ring installation. (3)
1. Don't open the seal ring wider than necessary. Be careful not to bend the claws.
B. One-way clutch thrust washer No. 1 installation. (2)
1. Install the thrust washer to the sun gear input drum while aligning its convex with the hole of the
drum.
C. One-way clutch assembly installation. (1)
1. Install the one-way clutch assembly to the planetary sun gear in the direction shown in the
illustration.
Page 4224
CONTROL UNIT VIEW
Rear Differential Lock Control Unit I
Page 7216
RELAY VIEW
Intermittent Wiper Relay (Rear Wiper) H

Page 5439
1992-95 Montero Service Manual, Volume 1 page 37A-27 1996 & 1997 Montero Service Manuals,
Volume 1, page 37A-23 1998 & 1999 Montero Service Manuals, Volume 2, page 37A-24
2000 Montero Service Manual, Volume 2, page 37A-23
Camshaft Position Sensor: Component Tests and General Diagnostics
STEP 1. Check for continuity between the camshaft position sensor and the MFI relay.
- Camshaft position sensor connector: Disconnected
NOTE: -
Insert the probes of the circuit tester into both ends of the harness.
Camshaft position sensor connector: Disconnected OK: GO TO STEP 3 NG: Repair the harness.
(A1 - Ground)
STEP 3. Check for an open circuit or a short-circuit to ground between the camshaft position
sensor and engine control module. -
- Camshaft position sensor connector: Disconnected OK: GO TO STEP 4 NG: Repair the harness.
(A2 - 88)
Camshaft position sensor connector: Disconnected
Page 4006
INSPECTION
the ground.
Page 2978
SENSOR CHECK
Page 3811
1997 & 1998 Montero Sport Service Manuals, Volume 1, Page 23B-55 Change the forward clutch
piston stroke specifications as shown.
Page 5849
1997 3000GT Volume 1, page 52B-5
Page 5293
1999 Montero Sport Service Manual, Volume 3, Page 37A-13 Add the new steering angle
adjustment caution statement as shown.
Page 3271
Page 2776
Coolant Temperature Sensor/Switch (For Computer): Locations

SENSOR VIEW
Engine Coolant Temperature Sensor C
(for Engine Control)

Page 85
Headlamp Relay: Testing and Inspection
Headlight Relay And Tail Light Relay Check
Headlight And Taillight Relay Table
1. Remove the headlight relay or tail light relay from the relay box in the engine compartment. 2.
Apply battery positive voltage to terminal (2), and check for continuity between the terminals when
terminal (4) is grounded.
Page 2563
Page 5362
5. After disconnecting the battery cable, wait 60 seconds or more before proceeding with the
following work. The SRS system is designed to retain
enough voltage to deploy the air bag for a short time even after the battery has been disconnected,
so serious injury may result from unintended air bag deployment if work is done on the SRS system
immediately after the battery cables are disconnected.
6. SRS components should not be subjected to heat over 93°C (200°F), so remove the front impact
sensors, SRS diagnosis unit, air bag module and
clock spring before drying or baking the vehicle after painting.
7. Whenever you finish servicing the SRS, check the SRS warning light operation to make sure that
the system functions properly. 8. Make certain that the ignition switch is OFF when the scan tool is
connected or disconnected. 9. If you have any questions about the SRS, please contact the MMSA
Teck Line.
NOTE: SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO
USE ONLY THE PROCEDURES AND EQUIPMENT SPECIFIED.
Page 4770
Hydraulic Assembly: Service and Repair
REPLACEMENT
1. Drain the brake fluid into a suitable container. 2. Remove the brake pipe connections. 3. Remove
the Hydraulic Unit (HU).
CAUTION: -
The HU is heavy. Take care when removing it.
- Do not loosen or remove any HU nuts or bolts.

- Do not drop or subject the HU to any shock.
- The HU must not be turned upside down or laid on its side.
- Ensure hydraulic system is bleed. See: Brake Bleeding/Service and Repair
- Test the HU for proper operation. See: Testing and Inspection

Page 5883
post-deployment handling instructions.
3. If the air bag module fails to deploy when the procedures above are followed, do not go near the
module. Contact the MMSA Teck Line.
11. Dispose of the air bag module after deployment according to the Deployed Air Bag Module
Disposal Procedures.
DEPLOYMENT OUTSIDE THE VEHICLE
CAUTION:
1. Should be carried out in a wide, flat area at least 6 m (20 feet) away from obstacles and other
people. 2. Do not perform deployment outside, if a strong wind is blowing, and if there is even a
slight breeze, the air bag module should be placed and
deployed downwind from the battery.
1. Disconnect the negative (-) and positive (+) battery cables from the battery terminals, and then
remove the battery from the vehicle
CAUTION: Wait at least 60 seconds after disconnecting the battery cables before doing any further
work.
2. Remove the air bag module from the vehicle.
CAUTION: The air bag module should be stored on a flat surface and placed so that the pad cover
face up. Do not place anything on top of it.
3. Connect two wires, each six meters (20 feet) long or more, to the two leads of SRS AIR BAG
ADAPTER HARNESS B (driver's side) or SRS
AIR BAG ADAPTER HARNESS A (front passenger's side), and cover the connections with
insulation tape. The other ends of the two wires should be connected to each other
(short-circuited), to prevent sudden unexpected deployment of the air bag.
Driver's Side
Page 5909
NOTE: If the white or yellow roller cannot be seen or black roller can be seen, the neutral point is
not aligned correctly.
4. Install the clockspring to the column switch.
CAUTION: If the clock spring's mating mark is not properly aligned, the steering wheel may not
rotate completely during a turn, or the flat cable within the clock spring may be severed, obstructing
normal operation of the SRS.
Air Bag Module Installation
Step 2: Air Bag Module Installation
Route the horn switch harnesses as shown in the illustration, and then install the air bag module
without clamping the harnesses.
1. After installing the clock spring, the steering wheel, the column covers and the air bag module,
check steering wheel for noise, binds or difficult
operation.
2. Reconnect the negative battery terminal. Turn the ignition key to the "ON" position. Does the
"SRS" warning light illuminate for about 7 seconds,
turn off and then remain off for at least 45 seconds? If yes, SRS system is functioning properly. If
no, consult SRS Warning Light Inspection.
INSPECTION
Air Bag Module
If any improper part is found during the following inspection, replace the air bag module with a new
one.
Page 6664

Page 873
OPERATION
high to low.
Page 3057
Air Injection Vacuum Control Solenoid Valve: Description and Operation
- Pulses are produced in accordance with the vehicle speed, and vehicle-speed signals are input to
systems (the MFI system, etc.) that regulate according to the vehicle speed.
Page 2900


Intake Air Temperature Sensor: Diagram Information and Instructions
Page 4644


Page 1556


Page 6921
Wire Color Codes
the marking color.

Page 6415
Cruise Control Servo Cable: Adjustments
(1) Remove the link protector. (2) Check if there is any deflection in the inner cables of the
accelerator cable, cruise control cable and throttle cable.
If there is excessive deflection or no play in an inner cable, loosen the adjusting bolts and nuts to
release each link from the throttle lever. (Do not remove the adjusting bolts or nuts.)
Page 5843
Page 306
Specifications
Axle Shaft: Specifications
Total Backlash (Limit) ..........................................................................................................................

.......................................... 11 mm (0.43 inch)
Page 3140
Fillpipe Restrictor: Testing and Inspection
Remove the fuel filler cap and check the fillpipe restrictor for tampering. On models with more that
one fuel tank, check each tank filler tube.
Page 3297

Specifications
Crankshaft: Specifications
DIMENSIONS
End Play:
Standard
..........................................................................................................................................................
0.05 - 0.25 mm (0.0020 - 0.0098 inch) Limit ........................................................................................
.................................................................................................... 0.3 mm (0.012 inch)
Journal:
Outer Diameter ....................................................................................................................................

........................................... 64 mm (2.52 inch) Oil Clearance:
Standard
.................................................................................................................................................... 0.02
- 0.04 mm (0.0008 - 0.0016 inch) Limit ................................................................................................
...................................................................................... 0.1 mm (0.039 inch)
Out-Of-Round ......................................................................................................................................
.................................. 0.005 mm (0.0002 inch) Taper .........................................................................
............................................................................................................. 0.005 mm (0.0002 inch)
Pin:
Outer Diameter ....................................................................................................................................

.......................................... 55 mm (2.17 inch) Oil Clearance:
Standard Value
.......................................................................................................................................... 0.03 - 0.05
mm (0.0012 - 0.0020 inch) Limit ..........................................................................................................
............................................................................ 0.1 mm (0.004 inch)
Out-Of-Round ......................................................................................................................................
.................................. 0.005 mm (0.0002 inch) Taper .........................................................................
............................................................................................................. 0.005 mm (0.0002 inch)
Page 3848
B. First & reverse brake piston No. 2 removal. (21)
1. With the first & reverse brake piston No. 2 held, blow air into the transmission case through the
oil hole to remove the first & reverse brake
piston No. 2.
CAUTION: Do not blow air suddenly because the piston may be tipped and become hard to
remove.
C. Brake reaction sleeve removal. (23)
1. With the brake reaction sleeve held, blow air into the transmission case through the oil hole to
remove the brake reaction sleeve.
CAUTION: Do not blow air suddenly because the sleeve may be tipped and become hard to
remove.
D. First & reverse brake piston No. 1 removal. (25)
oil hole to remove the piston.
remove.
INSPECTION
Page 5944
CAUTION:

Specifications
Valve Clearance: Specifications
Intake Valves Hydraulic - Not Adjustable
Exhaust Valves Hydraulic - Not Adjustable

Page 3376
Throttle Full Close Switch: Description and Operation
OPERATION
- The closed throttle position switch functions to convert (to HIGH/LOW-level voltage) data as to
whether the accelerator is depressed or released, and to input that voltage (as signals) to the
engine control module. The engine control module, based upon those signals, regulates the idle air
control motor.
Page 4464
Page 3443
OPERATION
control motor.
Specifications
Turn Signal Switch: Specifications
Rated load ...........................................................................................................................................
............................................................... 6.6 ± 0.05 A Voltage drop ....................................................
.................................................................................................................................................. 0.2 V
or less
Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications Coil Resistance
Coil Resistance
Resistance 28 - 33 ohms at 68 deg F

Page 1819
Component View
Page 2954
Grounding Markings

Locations
Control Unit: Locations

Locations
Sunroof / Moonroof Drain: Locations

WIRING AND PIPING DIAGRAM
Hoses may be located in closed cross section components due to the body construction. When
replacing these components, first remove the hoses.
Page 4692
Transmission Position Switch/Sensor: Testing and Inspection
If the output of the park/neutral position switch is abnormal even though the results of the checking
of the park/neutral position switch harness and of the component itself are normal, the cause is
probably improper adjustment of the control cable.
INSPECTION Using Scan Tool
Ignition switch-ST
Park/Neutral Position Switch
HARNESS INSPECTION
STEP 1. Measure the power supply voltage of the park/ neutral position switch. -
- Ignition switch: START Voltage (V): Battery positive voltage OK: GO TO STEP 2 NG: Check the
power supply circuit.
STEP 2. Check for continuity between the park/neutral position switch and the engine control
module. -
NOTE: -
OK: GO TO STEP 3 NG: Repair the harnesses. (A5 - 71, A6 - 91)

Page 4065
Grounding Markings

Page 6294
RELAY VIEW
Door Lock Relay I

Page 6100
Page 2036

SENSOR VIEW

Steering - Cautions for Steering Angle Adjustment
Front Steering Knuckle: Technical Service Bulletins Steering - Cautions for Steering Angle
Adjustment
No: TSB-00-37A-001
DATE: October, 2000
MODEL: See Below
SUBJECT: ADDITION OF NEW STEERING ANGLE ADJUSTMENT CAUTION STATEMENT -

PURPOSE This bulletin contains a new caution statement relating to the steering angle
adjustment.
AFFECTED VEHICLES 1996-2000 Montero 1997-2000 Montero Sport
AFFECTED SERVICE MANUALS 1996 & 1997 Montero Service Manuals, Volume 1, Page 37A-8
1998, 1999 & 2000 Montero Service Manuals, Volume 2, Page 37A-8 1997 & 1998 Montero Sport
Service Manuals, Volume 2, Page 37A-7 1999 Montero Sport Service Manual, Volume 3, Page
37A-13 2000 Montero Sport Service Manual, Volume 2, Page 37A-13
MANUAL REVISIONS
Page 3050
SENSOR CHECK
Locations
Page 5279
a. Tie rod assembly disconnection (1).
Use the special tool to disconnect the tie rod ends, and then remove the tie rod assembly.
CAUTION: 1. Use cord to bind the special tool closely so it won't become separated. 2. The nut
should only be loosened, not removed.
b. Relay rod disconnection (6).
Use the special tool to disconnect the connecting portions of the idler arm and the steering gear
box, and then remove the relay rod.
c. Idler arm removal (8).
Use a bench press to remove the idler arm.
CAUTION: The nut should only be loosened, not removed.
INSPECTION
Component Check
Check the idler arm support for damage and deformation. Check the idler arm for damage and
deformation. Check the dust covers fro damage and cracks. Check the tie rods for damage and
deformation. Check the relay rod for bends and damage. check the grease nipples for clogging and
looseness.
Page 6622
on actual vehicles.
Wire Color Codes
Engine - Connecting Rod Identification Revision
Connecting Rod: Technical Service Bulletins Engine - Connecting Rod Identification Revision
No: TSB 08-11-002
DATE: April, 2008
MODEL: See Below
SUBJECT: CONNECTING ROD BEARING IDENTIFICATION - 6G74 & 6G75 ENGINES -

SERVICE MANUAL REV
PURPOSE
As the identification mark on the connecting rod for vehicles equipped with 6G74 and 6G75
engines has been eliminated, classifying the connecting rod big end diameter is no longer required.
Accordingly, the number of connecting rod bearing selections is reduced from 5 to 3.
This Technical Service Bulletin informs the bearing selection method for the new part.
NOTE:
This part is used on engines built with engine # TB9787. Refer to Section 00 - GENERAL of the
applicable Service Manual for further information on location of the engine number.
* The identification mark has been eliminated on the connecting rod at the position shown in the
drawing.
For bearing selections, refer to Attachment 1.

AFFECTED VEHICLE(S)
APPLICABLE MANUAL(S)
All Service Manuals for Applicable Vehicles. Due to the number of applicable Service Manuals,
individual page numbers are not provided. Apply this information to the appropriate pages in
section 11B - ENGINE OVERHAUL, of the applicable Service Manual.
INTERCHANGEABILITY
Fully interchangeable.
Fuse Block: Diagram Information and Instructions
Page 3531
Specifications
Dome Lamp: Specifications
Dome light ...........................................................................................................................................
............................................................................ 8 W
Page 3831
Overdrive Direct Clutch Piston Stroke
1. Install the oil pump to the torque converter. Install the overdrive direct clutch assembly to the oil
pump. 2. Using a dial gauge, measure the piston stroke by applying compressed air (400 - 800
kPa, 57 - 113 psi) into the oil hole of the oil pump as
shown and then releasing the air.
Standard value: 1.85 - 2.15 rum (0.0728 - 0.0846 inch)
If the stroke is out of this range, replace the clutch flange with an appropriate one so that the stroke
becomes within this range.
NOTE: When selecting the flange, aim at the center of the range.
ASSEMBLY
A. Overdrive planetary gear thrust washer No. 3 installation. (23)
1. Install the thrust washer so that its oil groove is oriented to the front side.
B. Overdrive one-way clutch installation. (22)
1. Install the clutch so that its claw openings are oriented to the front side as illustrated.
Page 1933
Page 5352
INSPECTION
Using Scan Tool

HARNESS INSPECTION
(A1 - 37)
control module.
Drive Belt Tension Check and Adjustment
Drive Belt: Testing and Inspection Drive Belt Tension Check and Adjustment
CHECKING
Check the belt tension by using a belt tension gauge or by applying 98 N (22 lbs.) of force to the
belt midway between the pulleys as shown in the illustration, and measure the deflection. The
values are as shown in the illustration.
Page 4558
CONTROL UNIT VIEW
4WD Indicator Control Unit D

Page 5923
Malfunction Lamp / Indicator: Description and Operation
The diagnosis unit monitors the SRS system and stores data concerning any detected faults in the
system. When the ignition key is in "ON" or "START" position, the SRS warning light should
illuminate for about 7 seconds and then turn off. That indicates that the SRS system is in
operational order. If the SRS warning light does any of the following, immediate inspection by an
authorized dealer is needed.
1. The SRS warning light does not illuminate as described above. 2. The SRS warning light stays
on for more than 7 seconds. 3. The SRS warning light illuminates while driving.
If a vehicle's SRS warning light is in any of these three conditions when brought in for inspection,
the SRS system must be inspected, diagnosed and serviced.
Page 911

Page 232


Page 3283
A (Float point "F") ................................................................................................................................

........................................................ 119.3 (4.69) in. B (Float point "E") ..............................................
........................................................................................................................................ 255.0
(10.03) in.
Page 253
Wire Color Codes
the marking color.

Page 592
Intake Air Temperature Sensor: Testing and Inspection
Because the intake air temperature of the intake air in the air cleaner, it indicates a temperature
different than the temperature of the outside air when the engine is running. Note that the
resistance of the intake air temperature sensor decreases when the temperature of the intake air
increases.
- The intake air temperature sensor terminal voltage becomes higher when the resistance of the
intake air temperature sensor increases, and becomes lower when the resistance decreases.
Consequently, the intake air temperature sensor terminal voltage varies in accordance with the
temperature of the intake air, becoming lower when the temperature of the intake air increases.
INSPECTION
Using Scan Tool
HARNESS INSPECTION
- 92)
STEP 2. Check for an open or short-circuit between the intake air temperature sensor and the
(A6 - 72)
Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions
Specifications
Oil Pressure Warning Lamp/Indicator: Specifications
Oil pressure warning light ....................................................................................................................
...................................................................... 1.12 W
Parking Brake Warning Switch: Testing and Inspection
1. Disconnect the connector of the parking brake switch, and connect an ohmmeter to the parking
brake switch and the switch installation bolt. 2. The parking brake switch is good if there is
continuity when the parking brake lever is pulled and there is no continuity when it is returned.
Synthetic Resin Parts - Heat Resistance Specifications
Exterior Moulding / Trim: All Technical Service Bulletins Synthetic Resin Parts - Heat Resistance
Specifications
NO.: TSB-96-42A-015
DATE: July, 1996
MODEL: All Models
SUBJECT: SYNTHETIC RESIN PARTS: HEAT RESISTANCE TEMPERATURE

SPECIFICATIONS
PURPOSE
This bulletin contains detailed information about heat resistance temperatures on synthetic resin
parts. The table lists all synthetic resin parts, the material name, the heat resistance temperatures,
and their major locations on the vehicle.
AFFECTED VEHICLES
All Mitsubishi vehicles.
BODY REPAIR MANUAL REFERENCES
All Body Repair Manuals, Section 5: Synthetic resin Parts

Page 2735
Rectangular wave pattern is output even when the engine is not started.
- Example 2
Cause of problem Damaged rectifier or vortex generation column
Unstable wave pattern with non-uniform frequency. However, when an ignition leak occurs during
acceleration, the wave pattern will be distorted temporarily, even it the volume air flow sensor is
normal.
Page 4040
Torque Converter: Application and ID
GENERAL INFORMATION
Type: With torque converter clutch. Engine stall speed rpm: 2,100-2,600
Page 1317
NOTE (1)
If the engine oil level is low, air is sucked from the oil screen and enters the oil passage.
(2) If the engine oil level is higher than specification, oil may be stirred by the crankshaft causing
the oil to mix with high quantities of air.
(3) If oil is deteriorated, air is not easily separated from the oil, increasing the quantity of air
contained in the oil.
(4) If air mixed with oil enters the high pressure chamber inside the lash adjuster from the above
causes, air in the chamber is compressed excessively while the valve is open. This results in the
production of abnormal noise when the valve is closed. This is the same phenomenon as that
observed when the valve clearance is excessive. The lash adjuster can resume normal function
when air that has entered the lash adjuster is removed.
2. Idle the engine for one to three minutes to warm it up
3. Repeat the operation pattern, shown in the illustration, at no load to check for abnormal noise.
(Normally the noise is eliminated after 10 to 30 repetitions of the operation.) However, if there is no
change in the noise after repeating the operation more than 30 times, the noise is probably caused
by something other than the lash adjuster.
4. After eliminating the abnormal noise, repeat the operation in the illustration five more times.
5. Run the engine at idle for one to three minutes to make sure the abnormal noise is eliminated
and does not return.
Page 6817

Page 5221
Centralized Relay
Page 4191
Assembly
Page 6998

Page 1532

Page 3046
Wire Color Codes
the marking color.

Engine Coolant Temperature Gauge Resistance Check
Temperature Gauge: Testing and Inspection Engine Coolant Temperature Gauge Resistance
Check
Engine Coolant Temperature Gage Resistance Check - Chart
Use an Ohmmeter to measure the resistance between the terminals
CAUTION: For inspection, use an ohmmeter which uses a measurement current of 4 mA or less.
Page 2966
SENSOR VIEW

Heated Oxygen Sensor (Front & Rear)
Oxygen Sensor: Locations Heated Oxygen Sensor (Front & Rear)

Page 4984
1997 Montero, Volume 1, page 26-16
Page 3741
Transmission Speed Sensor: Technical Service Bulletins MIL ON - DTC P1715 Procedure
Correction
No: TSB-98-23-005REV DATE: August, 1998 MODEL: See below
SUBJECT: ILLUMINATED AND/OR DTC P1715
This bulletin supercedes TSB-98-23-005, issued May, 1998, to correct procedure steps.
PURPOSE
The malfunction indicator lamp (MIL or "CHECK ENGINE" light) may illuminate and Diagnostic
Trouble Code P1715 may set in the engine control module (ECM). In addition, the transmission
control module TCM) has set DTC 31 (Input Shaft Speed Sensor) and/or DTC 32 (Output Shaft
Speed Sensor). The customer may report sluggish acceleration, with the transmission returning to
normal shifting after the ignition key is turned off, then back on.
This bulletin describes diagnosis and repair procedures to eliminate this condition.
AFFECTED VEHICLES
1996-98 Montero automatic transmission models produced before 10/97:
^ Up to VIN WJ003864
1997-98 Montero Sport automatic transmission models produced before 10/97:
^ Two-wheel drive models up to VIN WP024415
^ Four-wheel drive models up to VIN WP024406
PROCEDURE
1. Connect the MUT-II scan tool and check for diagnostic trouble codes (DTCs). On the repair
order, note any DTCs set in the ECM, and any DTCs set in the TCM. These DTCs must be noted
on the warranty claim. Erase the DTCs and go to Step 2.
2. Test drive the vehicle, maintaining a speed of 40 mph for at least one minute. Check the pulse
generator readings on the MUT-II transmission data list while driving.
NOTE:
On the data list, pulse generator "A" (A/T input shaft) is displayed as "PG-A." Pulse generator "B"
(A/T output shaft) is displayed as "PG-B."
^ The pulse generator "A" (A/T input shaft) reading is A/T input shaft rpm when driving and when
stopped, but will read 0 rpm when in 4th gear (overdrive). It should be about the same as engine
rpm when the vehicle is stopped and the transmission is in Park or Neutral.
^ The pulse generator "B" (A/T output shaft) reading should be 0 rpm when the vehicle is stopped.
It should increase with vehicle speed.
a. If the previously set DTC or abnormal pulse generator reading is found, go to Step 3.
b. If no DTC or abnormal pulse generator readings are found, go to Step 6.
3. Perform the following resistance checks:
a. Check the resistance of the appropriate pulse generator (which had a DTC or an abnormal
reading in Step 2) at the TCM connector through the sensor and wiring harnesses. Resistance
should be 560 - 680 ohms at 20°C (68° F). If within specification, check the sensor rotor as
described in Step 4. If out of specification, go to Step 3b.
1997-98 Montero circuit diagram is shown: For 1996 Montero, refer to Vol.2, page 141.
Page 4197
Use the special tool to press-fit the side bearing inner races into the differential case.
CAUTION: When only one side bearing inner race is installed, place a load on the differential case
only.
G. Bearing cap installation. (28)
Align the mating marks on the gear carrier and the bearing cap, and then tighten the bearing cap.
H. Final drive gear backlash adjustment. (-)
Adjust the final drive gear backlash by the following procedure:
1. Use the special tool to provisionally tighten the side bearing nut until it is in the state just before
preloading of the side bearing.
2. Measure the final drive gear backlash.
Standard value:
Vehicles without rear differential lock: 0.13-0.18 mm (0.0051-0.0071 inch) Vehicle with rear
differential lock: 0.12-0.18 mm (0.0047-0.0071 inch)
NOTE: Measure at four points or more on the circumference of the drive gear.
3. Use the special tool (MB990201) to adjust the backlash to the standard value by moving the side
bearing nut as shown.
NOTE: First turn the side bearing nut for loosening, and tines turn the side bearing nut for
tightening by the same amount.
Page 1709
GAP

Page 4324
AFFECTED VEHICLES
1995-99 Montero
PROCEDURE
** Use the chart above to determine repair steps. Note that the 1998-99 model vehicles already
have the sound reduction sheets, and the different body mounts.
** PROPELLER SHAFT REPLACEMENT (1995-99 Models built before 8/25/98)
1. Referring to section 25 in the service manual, replace the propeller shaft with the new
B.J./damper-type shaft (1995-97 models) or the long-yoke B.J.-type propel or shaft (1998-99
models built before 8/25/98).
NOISE REDUCTION SHEET INSTALLATION (1995-97 MODELS)

Mechanical Specifications
Tires: Mechanical Specifications
Tread Depth Of Tire:
Limit .....................................................................................................................................................
........................................... 1.6 mm (.06 inch)
Page 2030
Camshaft Position Sensor: Service and Repair
Removal
Installation
Page 3100
on actual vehicles.
Wire Color Codes
Control Module: Testing and Inspection
Part 1 Of 3
Page 1875
Water Pump: Testing and Inspection
- Check for water leakage. If water leaks from hole "A" seal, unit is faulty. Replace as an assembly.
- Check the seal unit for leaks, and replace the water pump assembly if necessary.
- Check each part for cracks, damage or wear, and replace the water pump assembly if necessary.
- Check the bearing for damage, abnormal noise and sluggish rotation, and replace the water pump
assembly if necessary.
Page 314
Wheel Speed Sensor: Service and Repair
FRONT REPLACEMENT
1. Remove the clip and front speed sensor.
CAUTION: Be careful when handling the pole piece at the tip of the speed sensor and the toothed
edge of the rotor so as not to damage them by striking against other parts.
2. Remove the clip and harness bracket. 3. Remove the front rotor. Refer to "Transmission and
Drivetrain." 4. Reverse procedure to install, noting the following:
Page 6343
1997 Montero Service Manual, Volume 2, Page 191 Add connector 1 as shown and replace the
crossed-out diagram with the new diagram on the next page of this bulletin:
Page 1422
Rocker Arm Assembly: Specifications
Mounting Bolts .....................................................................................................................................

............................................... 31 Nm (23 ft. lbs.)
Page 406
SENSOR VIEW
Geomagnetic Sensor (built into multi meter) M

Page 5452
a. Anchor arm assembly adjusting nut loosening.
Loosen the anchor bolt of the torsion bar all the way.
NOTE: When the anchor arm assembly adjusting nut is loosened, use a jack to support the lower
arm of the side to be loosened to make the work easier.
b. Upper ball joint and knuckle disconnection.
Use the special tool to disconnect the upper arm ball joint from the knuckle.
CAUTION: 1. Be sure to tie the cord of the special tool to the nearby part. 2. The nut should only be
loosened, not removed.
INSPECTION
1. Check ball joint breakaway torque.
a. After shaking the ball joint stud several times, install the nut to the stud and use the special tool
to measure the breakaway torque of the ball
joint. Standard value: 0.8-3.5 Nm (7-30 inch lbs.)
b. When the measured value exceeds the standard value, replace the ball joint. c. When the
excessive play. If so, it is possible
to use that ball joint.
BALL JOINT DUST COVER REPLACEMENT
1. Remove the dust cover.
2. Apply multipurpose grease to both the interior of dust cover and the upper ball joint.
INSTALLATION

Page 5786
RELAY VIEW
Blower Motor Relay G

Page 133

Page 2117
OPERATION
Page 5388
Steering Gear: Service and Repair Overhaul
DISASSEMBLY
a. Pitman arm removal (2).
Use the special tool to remove the pitman arm from the gear box assembly.
Page 195
scan tool.
NOTE -
Page 4937
Vacuum Brake Booster: Service and Repair

1. Drain the brake fluid. 2. Remove the fluid level connector and sensor. 3. Remove the brake tube
connection. 4. Remove the master cylinder assembly. 5. Remove the vacuum hose with built-in
check valve.
NOTE: Since the check valve is fitted to the vacuum hose, replace the check valve as an assembly
unit together with the vacuum hose if there is a malfunction of the check valve.
6. Remove the vacuum pipe, cotter pin, washer and clevis pin. 7. Remove the booster, spacer and
sealant. 8. Reverse procedure to install, noting the following: 9. Replenish the reservoir with new
brake fluid. Bleed the master cylinder and the hydraulic system.
10. Adjust the brake pedal. See: Brake Pedal Assy/Adjustments 11. Adjust the clearance (A)
between the brake booster push rod and primary piston. See: Hydraulic System/Brake Master
Cylinder/Adjustments
Page 2137
on actual vehicles.
Wire Color Codes
Page 940
Gear Sensor/Switch: Testing and Inspection
INSPECTION
Center Differential Lock Detection Switch Check
Check the continuity between the brown connector terminal on the side of the transfer case and the
transfer case.
Transfer control lever position: Continuity 4H: No Continuity 4HLc: Continuity
2WD/4WD Detection Switch Check
Check the continuity between the black connector terminal on the side of the transfer case and the
transfer case.
Transfer control lever position: Continuity 2H: Continuity 4H: No Continuity
Center Differential Lock Operation Detection Switch Check
Check the continuity between the brown connector terminal on the top of the transfer case and the
transfer case.
4WD Operation Detection Switch Check

Control Unit: Diagram Information and Instructions
Component Locations

Page 6741


Page 2977
Vehicle Speed Sensor: Testing and Inspection
If there is damaged or disconnected wiring or a short-circuit in the vehicle speed sensor signal
circuit, the engine may stall when the vehicle speed is reduced and the vehicle is stopped.
HARNESS INSPECTION
STEP 1. Check for continuity in the vehicle speed sensor output circuit. -
- Move the vehicle. Continuity: Continuity and no-continuity are repeated alternately. OK: GO TO
STEP 4 NG: GO TO STEP 2
STEP 2. Check for an open or short-circuit between the vehicle speed sensor and the engine
control module. -
- Vehicle speed sensor connector: Disconnected OK: GO TO STEP 3 NG: Repair the harness. (A1
- 86)
Vehicle speed sensor connector: Disconnected OK: GO TO STEP 4 NG: Repair the harness. (B13
- Ground)
STEP 4. Measure the applied voltage.

Page 4845
1997 Montero Sport Service Manual, Volume 1, Page 27-19 Add the new service information as
shown.
Page 746
connected.)
connector.
increased.
Page 4847
shown.
Page 6906
Page 2687
10. A monitor indicates that reprogramming is in progress.
There are five phases in the reprogramming process. The VCI will continue with the process
automatically. Do not press any key.
Step 1: Saves data to the back-up memory. Step 2: Erases data in the ECU. Step 3: Writes new
data in the ECU. Step 4: Verifies the new data is transferred. Step 5: Erases diagnosis and back-up
memory.
11. The new ECU part number and ROM-ID display.
You must turn the ignition switch to OFF to complete the reprogramming process.
12. Start the engine and disconnect the MUT-III.
III. Error List

Page 1711
Spark Plug: Testing and Inspection
Spark Plugs
Check the plug gap and replace if the limit is exceeded.

Standard Value: 1.0 - 1.1 mm (0.39 - 0.43 in.)
Limit : 1.3 mm (0.051 in.)
CAUTION: 1. Do not attempt to adjust the gap of the platinum plug. 2. Cleaning of the platinum
plug may result in damage to the platinum tips. Therefore, if carbon deposits must be removed, use
a plug cleaner and
complete cleaning within 20 seconds to protect the electrode. Do not use a wire brush.
Spark Plug Cable
1. Check the cap and coating for cracks. 2. Measure resistance.
Limit : Max. 22 K Ohms

Page 1145
CAUTION:

Page 5931
CONTROL UNIT VIEW
SRS Air Bag Control Unit D
Page 6036
PARTS INFORMATION
Page 2291
THROTTLE POSITION SENSOR CHECK
(2) Measure the resistance between terminal (1) (sensor ground) and terminal (4) (sensor power).
Standard value: 3.5 - 6.5K Ohm
(3) Connect a pointer type ohmmeter between terminal (1) (sensor ground) and terminal (3)
(sensor output). (4) Open the throttle valve slowly from the idle position to the full open position and
check that the resistance changes smoothly in proportion with
the throttle valve opening angle.
(5) If the resistance is outside the standard value, or fails to change smoothly, replace the throttle
position sensor.
TPS installation torque: 2.0 Nm (1.5 ft.lbs.)

Page 7072
Brake Light Switch: Service and Repair
1. Remove the stop lamp switch connector. 2. Remove the stop lamp. 3. Reverse procedure to
install, ensuring proper shift lock cable adjustment and proper brake pedal adjustment (refer to
Brake and Traction Control).
For California
Cruise Control Servo: Locations For California
Solenoid, Solenoid Valve Location Views A - B
COMPONENT VIEW
Cruise Control Actuator (with built-in B
control valve and release valve)

Page 2930

Locations
Cruise Control Module: Locations
Control Unit Location Views A - B
CONTROL UNIT VIEW
Cruise Control Unit A

Fuel Pump Relay - Circuit Identification Corrections
Fuel Pump Relay: Technical Service Bulletins Fuel Pump Relay - Circuit Identification Corrections
NO: TSB-99-13-006 DATE: August, 1999 MODEL: 1997-99 Montero
SUBJECT: MFI CORRECTION, FUEL PUMP RELAY IDENTIFICATION AND CHECKING -

PURPOSE This bulletin contains corrections relating to identification and checking of the fuel pump
relay.
AFFECTED VEHICLES
1997-99 Montero
AFFECTED SERVICE MANUAL
1997 Montero Service Manual, Volume 1, Page 13A-58 1998 Montero Service Manual, Volume 1,
Page 13A-60 1999 Montero Service Manual, Volume 1, Page 13A-91, 92

Page 1915
CONTROL UNIT VIEW
Engine Control Module C
Page 147
Page 648

Page 5302
1. Install the tie rod assembly so that the dimension is as shown in the illustration.
NOTE: The illustration at left shows the left-side tie rod assembly. The right-side tie rod assembly is
symmetrical to the left-side assembly.
2. Adjust the pipe so that the difference between dimensions a and b is 1.5 mm (.059 inch) or less,
and then provisionally tighten the lock nut.
NOTE: Fully tighten the lock nut after the tie rod assembly is installed to the body and the toe-in
has been adjusted.
b. After installation steps do front wheel alignment adjustment (toe-in).

Page 916
Page 5563
Wire Color Codes
the marking color.

Power Steering Pump: Mechanical Specifications
Vane Type
Displacement ................................................................................................................................ 9.6

cm3 per revolution (.59 cubic inch per revolution)
Oil Pump Bracket Bolts ........................................................................................................................

................................................. 44 Nm (33 ft.lbs.) Oil Pump Pulley Cover Bolt ...................................
............................................................................................................................. 5 Nm (48 inch lbs.)
Idler Pulley Nut ....................................................................................................................................
................................................. 49 Nm (36 ft.lbs.) Idler Pulley Bracket Bolt ........................................
............................................................................................................................... 24 Nm (17 ft.lbs.)
Power Steering Pressure Hose Nut
........................................................................................................................................................ 20
Nm (14 ft.lbs.)
Page 2664
Grounding Markings

Page 6505
Inclinometer: Service and Repair
Disassembly Steps
Disassembly
Reassembly

Page 3587
Crankshaft Position Sensor: Locations

SENSOR VIEW
Crankshaft Position Sensor H

Page 3989
INSPECTION
Page 3262
RELAY VIEW
Fuel Pump Control Relay F

Page 1517
Oil Pan: Fluid Type Specifications
Sealant
.................................................................................................................................................
Mitsubishi Genuine P/N MD970389, Or Equivalent
Specifications

Page 6727
SENSOR VIEW

Page 5361

- Clock Spring
- Air Bag Module
Service Precautions
table.
SRS-ECU Connector
Page 722
on actual vehicles.
Wire Color Codes
Locations

Page 2235
Page 6868

Page 2993
pushed.

malfunction.
Page 4326
the vehicle.
rear springs.
NOTE:
Page 131

Oxygen Sensor: Diagram Information and Instructions
Page 4904
Brake Master Cylinder: Adjustments
CLEARANCE CHECK
Calculate clearance A from the B, C and D measurements. A = B - C - D. The standard value is

0.65-0.90 mm (0.026-0.035 inch). If the clearance is not within the standard value range, adjust by
changing the push rod length by turning the screw of the push rod.
NOTE: When brake booster negative pressure -93.3 kPa (27.6 in. Hg) is applied, clearance value
will become 0.05-0.30 mm (0.0020-0.0120 inch).
Page 511
Wire Color Codes
the marking color.

Headlamp Switch: Description and Operation
- If the passing switch is set to the ON position when the ignition switch is at the ACC or ON
position and the lighting switch is at the OFF or TAIL position, the low beams and high beams will
illuminate simultaneously when the dimmer switch is at the LO position, and the high beams will
illuminate when the dimmer switch is at the HI position.
Page 5997
1997 Montero Service Manual, Volume 2, Page 54-78 Correct the motor antenna and control unit
inspection procedures as shown.
Page 1177
Centralized Relay
Crankshaft Position Sensor: Component Tests and General Diagnostics
Hint 1: If an impact is suddenly felt during driving or the engine suddenly stalls during idling, try
shaking the crankshaft position sensor during idling. If the engine stalls, the cause is probably
improper or incomplete contact of the crankshaft position sensor's connector. Hint 2: If the
crankshaft position sensor output r/min is 0 r/min during cranking when the engine cannot be
started, the cause is probably a malfunction of the crankshaft position sensor or a broken timing
belt. Hint 3: If the indicated value of the crankshaft position sensor output r/min is 0 r/min during
cranking when the engine cannot be started, the cause is probably a failure of the ignition coil's
primary current to intermittently pulse correctly, so a malfunction of the ignition system circuitry, the
ignition coil and/or the power transistor is the probable cause. Hint 4: If idling is possible even
though the crankshaft position sensor indicated r/min is outside the standard value, the cause is
usually a malfunction of something other than the crankshaft position sensor. Examples: (1)
Malfunction of engine coolant temperature sensor (2) Malfunction of idle air control motor (3)
Incorrect adjustment of the standard idling speed.
INSPECTION
Using Scan Tool
NOTE: When idling to warm up from an engine coolant temperature of approx. -20°C (-40°F), if the
idling revolution is lower than the standard value even when the IAC motor is fully opened, the air
volume limiter built in the throttle body could be defective.
HARNESS INSPECTION
STEP 1. Check for continuity between the crankshaft position sensor and the MFI relay. -
- Crankshaft position sensor connector: Disconnected
NOTE:
Page 4957
Electronic Brake Control Module: Locations

Air Flow Meter/Sensor: Diagram Information and Instructions
Page 2265

Page 4423
Wire Color Codes
the marking color.

Customer Safety Information
Air Bag(s) Arming and Disarming: Customer Safety Information

SRS Maintenance
The SRS must be inspected by an authorized dealer up to 10 years after the car manufacture date.
Warning/Caution Labels
A number of caution labels relating to the SRS are found in the vehicle, as shown in the following
illustration. Follow label instructions when servicing SRS. If labels are dirty or damaged, replace
them with new ones.
A. WARNING
This vehicle has an air bag system. Refer to service manual before servicing or disassembling
underhood components. Read the "SRS" section of manual for important instructions. Improper
service procedures can result in the air bag firing or becoming inoperative, possibly leading to
injury.
Page 328

SENSOR VIEW

Locations
Vehicle Speed Sensor: Locations

Page 1038
Drive Belt: Adjustments A/C
1. Loosen the tension pulley fixing nut. 2. Adjust the belt tension using the adjusting bolt. 3. Tighten
the fixing nut. 4. Crank the engine once or more. 5. Check the belt tension.
Page 5173
Centralized Relay
Page 643
Component View
Power Steering Pressure Switch D
Page 5976
SENSOR VIEW

Page 1107
Power Steering Fluid: Service and Repair Fluid Replacement
Check for contamination in the fluid reservoir. Foamy or cloudy fluid should be replaced. 1.
Remove the reservoir cap. 2. Disconnect the return hose from the reservoir tank and remove the
fluid. 3. Disconnect the high tension cable. 4. Run the engine intermittently several times with the
starting motor to remove the fluid from the gear box. 5. Attach the return hose and fill with the
specified automatic transmission fluid.
Specified fluid: Automatic transmission fluid "DEXRON II"
6. Bleed the system and check the fluid pressure.

Page 3967
Oil Pressure Gauge Check
Oil Pressure Gauge: Testing and Inspection Oil Pressure Gauge Check
Oil Pressure Gage Check
Use an ohmmeter to measure the resistance between the terminals. Standard value : Approx. 50
Ohms
Page 3696

Page 3032
Transmission Position Switch/Sensor: Description and Operation
OPERATION
The engine control module regulates fuel injection during starting, etc. based on those signals.
- When the ignition switch is set to START, the battery positive voltage during engine cranking is
applied to the engine control module by way of the ignition switch and the park/neutral position
switch, and the engine control module thus detects the fact that the engine is cranking. Note that
battery positive voltage is not applied to the engine control module if the selector lever is in a
position other than P or N.
- The park/neutral position switch functions to convert the voltage to HIGH level or LOW level
depending upon whether the selector lever is in the P or N position or is at some position other
than P or N, and inputs the result to the engine control module. The engine control module, based
upon those signals, then regulates the operation of the idle air control motor.
- Battery positive voltage inside the engine control module is applied via the resistance to the
park/neutral position switch. When the selector lever is placed in the P or N position, continuity is
created, between the engine control module's park/neutral position switch terminal and the ground
via the starter motor, and the terminal voltage becomes low.
Page 2741

Page 1417
condition.
NOTE
CAUTION
Locations
Power Seat Relay: Locations
Relay Location View K
RELAY VIEW
Power Seat Relay Box K

Page 5033
Battery: Technical Service Bulletins Tool - Battery/Starting/Charging System Analyzer
No: TSB-01-00-011 REV DATE: July, 2001 MODEL: All
SUBJECT: MIDTRONICS MICRO530(TM) BATTERY/STARTING/CHARGING SYSTEM

ANALYZER
PURPOSE
This bulletin introduces a new essential tool, the Midtronics Micro530(TM)

Battery/Starting/Charging System Analyzer along with related procedures and information.
Diagnosing battery-related conditions can be difficult, even for experienced technicians. Good
batteries are often replaced when simply charging the battery would restore it. The Midtronics
Micro530(TM ) Battery/Starting/Charging System Analyzer will enable dealership technicians to
effectively, accurately, and safely test a battery in less than 10 seconds.
The Midtronics Micro530(TM) is a compact, easy-to-use tester, using conductance technology to

measure a battery's ability to produce current. Conductance is used to determine the battery's true
state and provide an indication of the battery's remaining life.
In addition to battery testing, the Micro530(TM) is capable of starting and charging system analysis.
The Midtronics Micro530(TM) provides technicians with one of five possible decisions on the
current health of the battery:
^ Good Battery - The battery is in good condition
^ Good-recharge - Battery is in good condition, but is a low state of charge. Recharge.
^ Charge & Retest - Fast charge the battery and retest. Most batteries can be charged for retesting
in as little as 30 minutes.
^ Replace Battery - Replace the battery, battery is not in serviceable condition
^ Bad Cell-Replace - DO NOT charge the battery. It has a damaged cell, or possibly a short.
Knowing the actual condition of the battery can also help determine when and if additional charging
system troubleshooting, analysis, diagnosis, and repair are required.
AFFECTED VEHICLES All
PROCEDURE
Page 2544
CONTROL UNIT VIEW
Page 3295

Page 2703
Alternator
Drive Belt: Adjustments Alternator
ALTERNATOR AND POWER STEERING PUMP
1. Loosen the tension pulley fixing nut. 2. Tighten the fixing nut temporarily to 9.8 - 19.6 Nm (7 - 14
ft. lbs.). 3. Adjust the belt tension using the adjusting bolt. 4. Tighten the fixing nut. 5. Crank the
engine once or more. 6. Check the belt tension.
Page 2553
Engine Control Module: Connector Views

Specifications
Overdrive Indicator Lamp: Specifications
Overdrive off indication light ................................................................................................................
..................................................................... 1.12 W
Page 4849
shown.
Fuel Gauge Sender: Electrical Specifications
Fuel Gauge Unit
Fuel Gauge Unit is a Variable Resistance type gauge unit.
Fuel Gauge Unit Resistance
Float Point "F" ......................................................................................................................................

................................................................ 3 ± 2 Ohm Float Point "E" ..................................................
................................................................................................................................................ 110 ± 7
Ohm
Page 490

Page 1190
Recall - Rear Cargo Mat
Seat Latch: All Technical Service Bulletins Recall - Rear Cargo Mat
NO: SR-98-004
DATE: October, 1998
MODEL: 1994-98 Montero
SUBJECT: REAR CARGO AREA MAT MODIFICATION - SAFETY RECALL CAMPAIGN
PURPOSE
Mitsubishi Motor Sales of America, Inc. (MMSA) is voluntarily recalling certain 1994-98 Montero
vehicles to modify the rear cargo area carpet (mat).
Description of Defect
MMSA adds an accessory cargo mat in the third-seat/cargo area. This mat is placed into the
vehicle at the ports then subsequently installed at the dealership during PDI. Upon cargo mat
installation, the third-seat strikers are surrounded by two layers of carpeting, (1) the cargo mat on
top, and (2) the factory installed carpet beneath. The fold-down third seats must latch onto these
strikers. The cargo mat may interfere with the latching integrity of the folding third seats.
Remedy
All owners of potentially affected vehicles will be notified to bring in their vehicles for inspection and
modification. The cargo area mat will be inspected to see if it requires modification and modified if
necessary. The third-seat strikers and latches will also be inspected. Mats that require modification
will have "T"-shaped holes for the strikers. These mats will be modified by cutting out two
rectangles of carpet surrounding the "T"-shaped striker holes. The mat will then be reinstalled and
the third-seat latching performance will be verified.
AFFECTED VEHICLES 1994-98 Montero equipped with the package which includes the cargo
area mat
NOTE:
A list of potentially affected vehicles invoiced to your dealership is included with this bulletin. All
vehicles in your dealership inventory should be inspected and modified if the cargo mat has the
"T"-shaped holes. Some vehicles may have mats which have already been modified so not all units
will require repair.
CUSTOMER NOTIFICATION
Page 6283
Technical Service Bulletin # 9251001 Date: 920501
Paint - Damage Identification and Repair
NO.: TSB-92-51-001
DATE: MAY 1992
MODEL: ALL MODELS
SUBJECT: PAINT DAMAGE IDENTIFICATION AND REPAIR PROCEDURES
PURPOSE
This bulletin provides technical information and procedures for identifying and repairing various
types of paint damage on all new vehicles, as well as proper inventory care to minimize future
damage.
Acid Rain, Industrial Fallout, Rail Dust or Scratches & Swirl Marks is classified as Industrial paint
damage. Other damage, such as tree sap, bird droppings or bee pollen, is classified as Organic
paint damage.
NOTE:
More detailed information on this subject can be found on the Triple Diamond Communications II
Video # 44, Paint Damage & Repair.
Paint Coatings
There are several types of paint coatings on our vehicles, depending on the model. Each body
panel gets a pre-treatment coating, a protective coating and a coat of primer. Next, over the primer,
is the color coat. On some models a clearcoat is also applied.
Solid Color
The solid color is applied to a combined minimum thickness of 2.75 mils, (.00275"). Some solid
colors (Precis, Eclipse) get a clearcoat. On these colors the minimum combined thickness is 3.25
mils, (.00325").
NOTE:
To check if the vehicle has a clearcoat, use a clean cotton towel and rub some paint cleaner on an
out-of-the-way spot, such as a lower body panel. If you see paint on the cloth in the color of the
vehicle, then most likely there is no clearcoat. Some paint coatings have a tinted clear.
Metallic
For metallic paint a clearcoat is applied over the color coat. Overall minimum thickness for metallic
paint will measure over three thousandths, (.00325"), 3.25 mils.
Pearl
For pearl color, such as the 3000GT and the Diamante, a pearlcoat is applied over the color
basecoat, and then the clearcoat. Overall minimum thickness for this application will measure 3.75
mils, (.00375").
Identifying Paint Coatings
To identify the type of paint used on any Mitsubishi vehicle, check the Vehicle Information Code
Plate for the exterior color code. On most of our vehicles this plate is located under the hood on the
bulkhead. Next, refer to the latest Technical Service Bulletin (TSB-91-51-005) to identify the
different types of finish on late-model vehicles.
Vehicle Inspection
Examine each vehicle at the time of delivery to see if it needs to be repaired now before the
damage gets worse sitting on the lot. Wash every vehicle for a close inspection. it's surprising how
grit can damage the surface even as you wash the car.
How to Measure Paint Thickness
Paint thickness is measured with a mii gauge. A mil gauge measures paint thickness from the top
of the sheet metal to the top surface of the coating. There are several different types of gauges.
Some gauges are digital and some are mechanical. Take several measurements in the area you
will be working on. Keep track of these measurements as you will re-measure later to ensure you
don't remove more than 0.5 mil (.0005"). This specification applies to all types of paint coatings.
Recommended Mil gauges:

Page 5767
Refrigerant: Testing and Inspection
SIGHT GLASS REFRIGERANT LEVEL TEST
The sight glass is a refrigerant level indicator. To check the refrigerant level, clean the sight glass
and start the vehicle engine. Push the air conditioning button to operate the compressor, place the
blower switch to high and move the temperature control lever to max cool. After operating for a few
minutes in this manner, check the sight glass.
1. If the sight glass is clear, the magnetic clutch is engaged, the compressor discharge line is warm
and the compressor inlet line is cool; the system
has a full charge.
2. If the sight glass is clear, the magnetic clutch is engaged and there is no significant temperature
difference between compressor inlet and discharge
lines; the system has lost some refrigerant.
3. If the sight glass shows foam or bubbles, the system could be low on charge. The system should
be checked to leak evacuated and recharged with
some refrigerant
Page 623
Grounding Markings

Fuel/Emissions - Sulfur Odor From Exhaust
Fuel: All Technical Service Bulletins Fuel/Emissions - Sulfur Odor From Exhaust
No: TSB-03-15-001 DATE: November, 2003 MODEL: All models
SUBJECT: SULFUR ODOR FROM EXHAUST
PURPOSE
Some customers may complain of a sulfur-like ("rotten egg") odor coming from the exhaust system.
Sulfur is a natural by-product of the gasoline refining process, and the amount of sulfur depends
upon the refinery's formulations. Sulfur content in fuel varies between gasoline brands and
locations.
AFFECTED VEHICLES All models
PROCEDURE
Exhaust sulfur odor does not necessarily indicate a vehicle concern, but is more likely to be directly
related to the fuel. If the vehicle has an excessive sulfur odor, check for any DTCs set in the PCM.
If any DTC is set, diagnose as described in the service manual.
If no vehicle problem is found, recommend the owner try a different brand of fuel. DO NOT
REPLACE ANY EMISSIONS COMPONENTS FOR SULFUR ODOR. PARTS REPLACEMENT
WILL HAVE NO EFFECT ON THE ODOR.
This complaint is NOT considered a warrantable condition. Repairs or replacements of catalytic

converters, oxygen sensors, or any other emissions components will have no effect on reducing or
eliminating the odor. Warranty claims submitted for such repairs or replacements will be charged
back.
Page 1912
retry.
ECU check error
Attachment A

Page 852

Locations
Cabin Temperature Sensor / Switch: Locations

Page 1332
Apply the information above to affected vehicles when a connecting rod is replaced with a new
part.
Page 1120
Refrigerant: Testing and Inspection
SIGHT GLASS REFRIGERANT LEVEL TEST
The sight glass is a refrigerant level indicator. To check the refrigerant level, clean the sight glass
and start the vehicle engine. Push the air conditioning button to operate the compressor, place the
blower switch to high and move the temperature control lever to max cool. After operating for a few
minutes in this manner, check the sight glass.
1. If the sight glass is clear, the magnetic clutch is engaged, the compressor discharge line is warm
and the compressor inlet line is cool; the system
has a full charge.
2. If the sight glass is clear, the magnetic clutch is engaged and there is no significant temperature
difference between compressor inlet and discharge
lines; the system has lost some refrigerant.
3. If the sight glass shows foam or bubbles, the system could be low on charge. The system should
be checked to leak evacuated and recharged with
some refrigerant
Page 6623
Wire Color Codes
the marking color.

Page 6595
Key Reminder Switch: Testing and Inspection
Ignition Switch Check
Key Reminder Switch

Page 3399
harnesses.
Page 3740
Component Locations

Page 3737
Page 654
INSPECTION
Using Scan Tool

HARNESS INSPECTION
(A1 - 37)
control module.
Page 2268
Wire Color Codes
the marking color.

Page 4597
Countershaft: Service and Repair
DISASSEMBLY
B. Roller bearing removal. (3)
ASSEMBLY

Page 3966
Wire Color Codes
the marking color.

With Automatic Transmission/Transaxle
Crankshaft Main Bearing Seal: Service and Repair With Automatic Transmission/Transaxle
1. Remove the transmission. 2. Refer to the illustration for the service procedure.
3. Use the flywheel stopper tool No. MD998781, or equivalent, to secure the drive plate, and
remove the bolts. 4. Cut out a portion in the camshaft oil seal lip.
A/C - Musty/Moldy Odors In Passenger Compartment
Evaporator Core: Customer Interest A/C - Musty/Moldy Odors In Passenger Compartment
No.: TSB-02-55-005 DATE: July, 2002 MODEL: All with A/C
SUBJECT: MUSTY ODORS FROM AIR CONDITIONING (A/C EVAPORATOR COIL

TREATMENT)
PURPOSE
This bulletin contains instructions for applying Mitsubishi Cooling Coil Coating to help eliminate
musty odors emanating from the air conditioner evaporator coils.
Symptom/Condition
The customer may complain of an unpleasant, "musty" odor in the passenger compartment when
the fan blower is switched on. This condition can be related to the area where the vehicle is
operated, occurring more often in humid climates.
Cause
The unpleasant "musty" odor from the air conditioner system occurs when condensation, which is a
normal occurrence, forms in and around the air conditioner's evaporator coil and mixes with
airborne pollutants and substances.
Remedy
To eliminate these odors, treat the air conditioner evaporator/cooling coil with Mitsubishi Cooling
Coil Coating. This coating will not only eliminate the odors, but will protect the evaporator coil.
On most vehicles, the coating can be applied onto the A/C evaporator coil surfaces through the
interior air recirculate door. This door is usually accessible from behind the glove box.
AFFECTED VEHICLES
All Mitsubishi vehicles equipped with air conditioning
PROCEDURES
IMPORTANT
Follow these procedures exactly. If you do not allow enough time for drying and curing, the coating
will wash away with the condensate, causing a comeback.
The complete treatment takes about 2 hours including drying and curing. Actual labor, however, is
about 20 minutes.
CAUTION
Safety Precautions to follow when using Mitsubishi Cooling Coil Coating
^ Keep out of reach of children.
^ Avoid contact with skin and eyes.
^ Wear skin and eye protection.
^ Avoid breathing vapors. Use a breathing protection mask (3M: 07185 is recommended).
If skin or eye contact occurs, wash skin or flush eyes with generous amounts of water.
1. Check the evaporator for airflow clogging or blockage by leaves or other foreign materials and
remove the blockage before proceeding.
NOTE:
If the buildup of the materials causing the clogging or blockage is excessive, replace the evaporator
assembly
Page 4307
Page 3488
OPERATION
ground.
Check
Vanity Lamp: Diagram Information and Instructions
Page 6512

Page 6546
Wire Color Codes
the marking color.

Page 4088
NOTE:
For 1997 Montero Sport models, refer to the circuit diagram on page 90-71 in Volume 2 of the 1997
Montero Sport service manual. For 1998 Montero Sport models, refer to the circuit diagram on
page 90-73 in Volume 2 of the 1998 Montero Sport service manual.
b. If the resistance reading in Step 3a was out of specification, check the resistance at the
appropriate pulse generator. Resistance should be 560 - 680 ohms at 20° C (68°F).
NOTE:
A difference of 5 ohms or more in the resistance reading taken at the TCM connector and the
reading taken at the sensor typically indicates that there is a problem in a harness or connector.
(1) If both pulse generators are within specification, check all associated harnesses for continuity.
Repair or replace the harness and/or connectors as necessary. Then go to Step 5.
(2) If both pulse generators are within specification and abnormal readings for pulse generator "B"
were found in Step 2, go to Step 4 for sensor rotor inspection.
(3) If pulse generator "A" is not within specification, replace it. Then go to Step 5.
(4) If pulse generator "B" is not within specification, it must replaced and the sensor rotor must be
inspected as described in Step 4.
4. Remove pulse generator "B" and inspect the sensor rotor for looseness or damage through the
mounting hole in the transmission case.
Page 3522
Component View
Ignition Coil C
Page 4827
Brake Caliper: Service and Repair Replacement
Front
NOTE:
- Refer to image for removal and installation.
- Bleed brake system. See: Brake Bleeding/Service and Repair
Rear
Rear Window Defogger Grid - Repair
Rear Defogger: Technical Service Bulletins Rear Window Defogger Grid - Repair
NO.: TSB-95-54-OO1
DATE: October, 1995
MODEL: All Models
SUBJECT: REAR WINDOW DEFOGGER GRID REPAIR
PURPOSE The rear window defogger grid lines can be damaged by improper window cleaning
procedures or by objects placed in the rear window area causing a small scratch on the grid line(s).
An open circuit results when the grid line is scratched or otherwise damaged.
Many rear window defogger grid lines can be repaired easily, quickly and economically by using a
Quick Grid(TM) REAR WINDOW DEFOGGER REPAIR KIT marketed by Loctite Corporation. The
kit, Loctite part number 15067, is available from auto jobbers and retail auto parts stores. If
unavailable from your usual source, call Loctite at 800-321-9188 and ask for Customer Service.
This repair kit may only be used on damaged defogger grid line areas four inches long maximum. It
is the only product tested by Mitsubishi Motor Sales of America, Inc. There may be other similar
products that are equally suitable for defogger grid repair.
PROCEDURE To use the Loctite kit, follow the manufacturer's instructions on the back of the kit.
To improve the appearance of the repaired grid section, wait 30 minutes after applying the repair
material, then carefully trim the excess material from the width of the repaired section with a sharp
blade.
WARRANTY INFORMATION Defogger Grid Repair
Nature Code: 99D Cause Code: 990
Labor Operation Number 42322125 Time Allowance: 0.6 hrs.

Warranty Coverage: 36 months/36,000 miles
Special Warranty Information: Defogger grid repair on an as needed basis.

Page 5679
Compressor Clutch: Testing and Inspection
MAGNETIC CLUTCH
1. Disconnect the wiring to the magnetic clutch. 2. Connect the positive battery terminal directly to
the wiring for the magnetic clutch. 3. If the magnetic clutch is normal, there will be a "click." If the
pulley and armature do not make contact ("click"), there is a malfunction.
Page 4026
INSTALLATION
the cable band.
Temperature Gauge: Electrical Specifications
Power supply and engine coolant temperature gage
..................................................................................................................................... 145 ± 14.5
Ohm Power supply and ground ...........................................................................................................
.................................................................. 115 ± 11.5 Ohm Engine coolant temperature gage and
ground ..............................................................................................................................................
246 ± 24.6 Ohm
Page 6163
Fuses and Fusable Links and IOD or Storage Connector
Fusible Link (Connected Directly To Battery Positive Terminal)

Page 2539
memory.
III. Error List

Page 1984

Page 3412
1996 Montero, 3.5L Engine

Page 7091
RELAY VIEW
Taillight Relay B
Page 1905
reprogramming.
Page 2269
Page 3558
Inspection
IGNITION COIL AND IGNITION POWER TRANSISTOR Using Scan Tool
HARNESS INSPECTION
STEP 1. Check for continuity between the ignition coil and the ignition switch-IG. -
Ignition switch connector: Disconnected
- Ignition coil connector: Disconnected
NOTE -
Touch the ohmmeter problems to both ends of the harness. OK: GO TO STEP 2NG: Repair the
harnesses. (A1 - E2, B1 - E2, C1 - E2)
Page 1153
Multi-Purpose Fuses (In Junction Block)
Page 6795

Specifications
Coolant Drain Plug: Specifications
Sealant
..........................................................................................................................................................
3M Nut Locking Part No. 4171, Or Equivalent
Replacement
Steering Gear: Service and Repair Replacement
REMOVAL
WARNING: Supplemental Restraint System (SRS).
- Before removal of steering gear box, center front wheels and remove ignition key. Failure to do so
may damage SRS clock spring and render SRS system inoperative, risking serious driver injury.
NOTE: Removal service points as follows:
a. Relay rod and pitman arm disconnection (5).
Use the special tool to disconnect the pitman arm from the relay rod.
CAUTION: 1. Use cord to bind the special tool closely so it won't become separated. 2. Loosen the
nut but do not remove it.
INSTALLATION

Page 3914
Overdrive Direct Clutch Disc
1. Using a micrometer, measure the thickness of the clutch disc.
Limit: 1.84 mm (0.0724 inch)
NOTE: The thickness must be measured at two or three points. Compare the average value with
the limit.
Overdrive Direct Clutch Piston
1. Check that the check ball is free by shaking the piston. 2. Check that the valve does not leak by
applying low-pressure compressed air.
Operation Of One-way Clutch
1. While holding the overdrive direct clutch drum, turn the input shaft clockwise to see that the shaft
turns smoothly and turn it counterclockwise
to see that the shaft is locked.
NOTE: -
If the shaft turns or locks in both directions, replace the one-way clutch.
- If the shaft turns counterclockwise while it doesn't turn clockwise, the one-way clutch may have
been assembled in the reverse direction.
Page 3099


Page 2293
harnesses.
Front Axle
Page 6821
Backup Lamp: Electrical Diagrams

Back-Up Light
Page 6583
Page 5900
Step 5: SRS Air Bag Control Unit (SRS-ECU) Installation
CAUTION: The SRS may not activate if SRS-ECU is not installed properly, which could result in
the SRS system not operating properly in a collision.
POST INSTALLATION INSPECTION
warning light illuminated for about 7 seconds , turn off and then remain off for at least 45 seconds?
If yes, SRS system is functioning properly. If no, consult SRS Warning Light Inspection.
INSPECTION
- Check the SRS-ECU case and brackets for dents, cracks or deformities.
- Check connectors and lock lever for damage, and terminals for deformities.
CAUTION: If a dent, cracks, deformation or rust is discovered, replace the SRS-ECU with a new
one.
NOTE: For checking of the SRS-ECU other than described above, refer to the section concerning
troubleshooting.
Page 5950

Snap Ring (For Adjustment of Center Differential End
Play)
Page 3351

Page 5265
Page 3998
REMOVAL
1. Remove front console assembly. 2. Follow removal steps outlined in illustration.
A. Transfer control lever assembly removal. (13)
When removing the transfer control lever assembly, move the transfer control lever to the 2H (2
wheel drive-high range) position.
INSPECTION
1. Check the transmission control cable assembly for function and for damage. 2. Check the outer
cable (key interlock cable, shift lock cable) for damage and check the spring for breakage and
correct tension. 3. Check the inner cable (key interlock cable, shift lock cable) for elongation.
Page 3117


Page 6360
Heated Seat (Part 2 Of 2)
Page 3654
Solenoid: Service and Repair
REMOVAL
Follow removal steps outlined in illustration.
INSTALLATION
A. Vacuum hose installation. (9)
Install the vacuum hoses so that the identification colors match those of the pipe assembly and the
actuator. Furthermore, there are no
Engine Control Module: Diagram Information and Instructions
Page 4230


Specifications
Countershaft: Specifications
End Play:
Counter Shaft Gear

............................................................................................................................................................
0-0.15 mm (0-0.0059 inch) Counter Shaft Gear Bearing
.............................................................................................................................................. 0-0.08
mm (0-0.0031 inch)
Page 5924
Malfunction Lamp / Indicator: Testing and Inspection
1. Check to be sure that the SRS warning light illuminates when the ignition switch is in the ON
position. 2. Check to be sure that it illuminates for approximately 7 seconds and then switches off.
3. If the above is not the case, inspect diagnostic trouble codes.

Page 1445
Valve Spring: Testing and Inspection
1. Measure the free height of the spring and, if it is smaller than the limit, replace.
Standard value is 51.0 mm (2.01 inch). Limit is 50.0 mm (1.97 inch).
2. Measure the squareness of the spring and, if the limit is exceeded, replace.
Standard value is 2°. Limit is 4° maximum.

Page 5569
INSTALLATION
the vehicle.
A: 1 - 2 mm (.04 - .08 inch) B: 1.5 - 2.5 mm (.06 - .10 inch)

Specifications
Interior Lighting Module: Specifications
Cigarette light illumination light ............................................................................................................
............................................................... 1.4 (74) W

Page 2085
Air Conditioning Switch: Testing and Inspection
INSPECTION
AIR CONDITIONING SWITCH
Operate the switch and use an ohmmeter to check for continuity between the terminals.
Page 6665


Page 6904
Wire Color Codes
the marking color.

Page 2232


Page 6670
Page 703
Grounding Markings

Page 4251
Fluid - Differential: Fluid Type Specifications
Front Differential and/or Conventional Rear Differential
API GL-5 or higher
Above -23°C (-10°F) ............................................................................................................................

....................................... SAE 90, 85W-90, 80W-90 From -34°C (-30°F) to -23°C (-10°F)
..................................................................................................................................................... SAE
80W, 80W-90 Below -34°C (-30°F) .....................................................................................................
......................................................................................... SAE 75W
Rear Limited Slip MITSUBISHI Genuine Gear Oil, Part No. 8149630 EX or equivalent
Page 1207
Tires: Pressure, Vacuum and Temperature Specifications
Tire Inflation Pressure
Front ....................................................................................................................................................
............................................... 180 kPa (26 psi) Rear ..........................................................................
.......................................................................................................................... 220 kPa (32 psi)
Seat Heater: Diagram Information and Instructions
Specifications
Connecting Rod Bearing: Specifications
Rod Journal Diameter 55.0 mm
Rod Bearing Clearance Service 0.2-0.5 mm
Limit 0.1 mm
Page 5478
Page 3177
HARNESS INSPECTION
NOTE: -
- 92)
control module. -
(A3 - 90, A7 - 19)

Application and ID
Wheel Bearing: Application and ID
GENERAL INFORMATION
Type: Taper roller bearing.

Specifications
Camshaft: Specifications
DIMENSIONS
Cam Height
Intake
Standard Value ....................................................................................................................................

............................... 37.58 mm (1.48 inch) Limit ..................................................................................
................................................................................................ 37.08 mm (1.46 inch)
Exhaust
Standard Value ....................................................................................................................................

............................... 36.95 mm (1.45 inch) Limit ..................................................................................
................................................................................................. 36.45 mm (1.44 inch)
Journal Diameter .................................................................................................................................

........................................... 44.93 mm (1.77 inch)
Specifications
......................................................... Approx. 50 Ohm
Page 1948
RELAY VIEW

Page 7041
Page 3939
NOTE: -
CAUTION: -

Locations
Fuse: Locations
Fusible Link, Fuse And IOD Or Storage Connector Location Overviews And Views A - D
Name Symbol
Dedicated Fuse No. 2,3,5,7 and 8 B
Dedicated Fuse No. 9 D
Fusible Links 1-7 A
IOD or storage connector B
Multi-Purpose Fuses C
Page 7012
Grounding Markings

Page 4819
Brake Caliper: Testing and Inspection
1. Tighten the disc/rotor to the hub with hub nuts. Measure hub torque (A) with the pads removed
using a spring balance. 2. Securely attach the pads and clips to the caliper support.
3. Clean the piston and insert into cylinder with disc brake piston expander tool No. MB990520. Be
careful that the piston boot does not become
caught, when lowering the caliper assembly and installing the lock pin.
4. Check the brake drag force (B) as follows. 5. Start the engine and hold the brake pedal down for
5 seconds. The pedal depression force should be approximately 196 N (44 pounds.) 6. Stop the
engine. 7. Turn the brake disc forward 10 times.
Check Hub Torque
8. Check the hub torque (B) with a spring scale. Calculate the drag force of the disc brake, the
difference between hub torque (B) and hub torque (A).
The standard value is 69 N (16 pounds) or less.
9. If the brake drag force exceeds the standard value, disassemble and clean the piston. Check for
corrosion or worn piston seal, and check the sliding
condition of the lock pin and Guide pin.

Page 6796


Page 5476
Page 1282
4. Check the rocker arms indicated by the white arrow in the illustration using the following
procedure.
FOR ALL EXCEPT THOSE ENGINES WITH Y-SHAPED ROCKER ARMS Check if the rocker arm
can be pushed down when pushing it at the portion just above the lash adjuster.
^ If the rocker arm can be pushed down easily, then the corresponding lash adjuster is defective.
^ If the rocker arm cannot be pushed down (it feels very stiff), the lash adjuster is in good condition.
In this case, investigate other causes for the abnormal noise.
FOR THOSE ENGINES WITH Y-SHAPED ROCKER ARMS
NOTE
The Y-shaped rocker arm on the exhaust valve side cannot be pushed down if either of the lash
adjusters is in good condition. So, use a feeler gauge to check the lash adjuster using the following
procedure.
a. Check if a 0.1 - 0.2 mm leaf of the feeler gauge can be inserted between the valve and the lash
adjuster.
b. If the leaf can be inserted, the corresponding lash adjuster is defective.

Page 3573


Specifications
Condenser HVAC: Specifications
.............................................................................................................. 40 cubic cm (1.4 fl. oz.)
Page 4390
Part 2 Of 3
Page 2314
Removal
Installation
Page 6181
A letter will be sent to all registered owners of affected vehicles. The letter instructs them to return
their vehicle to their Mitsubishi dealer to have this campaign procedure performed at no charge. A
copy of this customer letter is shown in this bulletin.
There may be some units which were sold and registered between the date you receive this
bulletin and recall campaign launch. You should contact any owner of a recently sold affected
vehicle and have them bring their vehicle in so the safety recall can be performed. Recent
purchasers may not receive a notification letter since their registration may not have been effective
in time for notification. It is very important that your dealership make every effort to contact these
customers so this safety recall campaign can be completed.
Page 6704
Seat Belt Reminder Lamp: Electrical Diagrams

Page 2414
HARNESS INSPECTION
NOTE: -
- 92)
control module. -
(A3 - 90, A7 - 19)

Page 897

Page 2100
Wire Color Codes
the marking color.

Specifications
Seat Belt Reminder Lamp: Specifications
Seat Belt Warning Light .......................................................................................................................
...................................................................... 1.12 W
Page 4438

Page 4703
Page 4084
Page 424
Key Reminder Switch

Page 880
Suspension Mode Switch: Service and Repair

Page 3980
Page 569
Grounding Markings

Page 250

Page 5694
RELAY VIEW
Condenser Fan Motor Relay B

Front Axle
Fluid - Differential: Testing and Inspection Front Axle
Remove the filler plug and check the gear oil level. Check that the gear oil level is not 8 mm (0.31
inch) below the bottom of the filler plug hole.
Specified gear oil: Hypoid gear oil API classification GL-5 or higher, SAE viscosity No. 9O, 80W
[1.15 dm3 (1.22 qts.)]
Page 2306
Wire Color Codes
the marking color.

Oxygen Sensor: Electrical Specifications Output Voltage
Output Voltage
Voltage 0.6 - 1.0 V

Page 4727
INSPECTION
transfer case.
transfer case.
transfer case.

Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Sensor

Resistance/Torque
Sensor Resistance/Torque
Resistance 5.8 K ohms at 32 deg F
2.4 K ohms at 68 deg F
Tightening Torque 22 ft.lb
Note: Use 3M locking nut part No. 4171 or equivalent.

Page 474


Page 4800
Brake Pedal Assy: Service and Repair
BRAKE PEDAL REPLACEMENT
1. Remove the brake pedal return spring. 2. Remove the cotter pin (No. 4), washer and clevis pin.
3. Remove the cotter pin (No. 7). 4. Remove the shift lock cable connection. 5. Remove the brake
pedal, bushing and spacer. 6. Remove the pedal support member. 7. Reverse procedure to install,
ensuring proper brake pedal adjustment. See: Adjustments
Page 2969

Page 2583
INSPECTION
Using Scan Tool
HARNESS INSPECTION
harness (A2 - 92)
- 77)
Page 1397
- Install the piston with the front mark (arrow mark) on the top of the piston directed towards the
engine front (timing belt side).
- Two types of pistons have been used, one for cylinders 1, 3 and 5 and the other for cylinders 2, 4
and 6. Pistons with an "R" are for cylinders 1, 3 and 5. Pistons with an "L" are for cylinders 2, 4 and
6.
20. Mate the correct bearing cap with the correct connecting rod by checking with the alignment
marks marked during disassembly. If a new
connecting rod is used which has no alignment mark, position the notches for locking the bearing
on the same side.
21. Check if the thrust clearance in the connecting rod big end is correct.
Standard value: 0.10 - 0.25 mm (0.0039 - 0.0098 inch) Limit: 0.4 mm (0.016 inch)
22. Before installation of each connecting rod nut, apply engine oil to the threaded portion and
bearing surface of the nut.
NOTE: Installation of the connecting rod nut should be performed with the cylinder head or the
spark plug removed. Since the connecting rod bolts and nuts are torqued using the plastic area
tightening method, the bolts should be examined before reuse. If the bolt threads are "necked
down", the bolt should be replaced. Necking can be checked by running a nut with fingers to the full
length of the bolt threads. If the nut does not run down smoothly, the bolt should be replaced.
23. Loosely tighten each nut to the bolt. 24. Then tighten the nuts alternately to a torque of 34 Nm
(25 ft. lbs.) to install the cap properly. 25. Make a paint mark on the head of each nut. 26. Make a
paint mark on the bolt end at the position 90 - 100° from the paint mark made on the nut in the
direction of tightening the nut. 27. Give a 90 - 100° turn to the nut and make sure that the paint
mark on the nut and that on the bolt are in alignment.
CAUTION: -
If the nut is turned less than 90°, proper fastening performance may not be expected. When
tightening the nut, therefore, be careful to give a sufficient turn to it.
- If the nut is overtightened (exceeding 100°), loosen the nut completely and then retighten it by
repeating the tightening procedure from step 22.
Page 2916
Wire Color Codes
the marking color.

Page 5138
Dedicated Fuse
Page 1454
Valve: Testing and Inspection
1. If the valve stem is worn (ridge wear) or otherwise damaged, replace as necessary. Also,
replace the valve if the stem end (the end that contacts the
rocker arm lash adjuster) has a dent.
2. Check the valve face for correct contact. If incorrect, reface using a valve refacer. Valve should
make a uniform contact with the seat at the center
of valve face.
3. If the margin exceeds the service limit, replace the valve.
Intake
Standard value: 1.0 mm (0.039 inch) Limit: 0.5 mm (0.019 inch)
Exhaust
4. Measure the valve total length. If the measurement is less than specified, replace the valve.
Intake
Exhaust

Page 6854


Page 4505
Wire Color Codes
the marking color.

Page 5651
SENSOR VIEW
Outside Air Temperature Sensor J

Page 6715


Page 575
Fuel Tank Pressure Sensor: Description and Operation
NOTE: For California models only.
OPERATION
- Fuel tank differential pressure sensor will convert the pressure in the fuel tank to voltage and input
it to the engine control module.
- 5 V of power is supplied to the fuel tank differential pressure sensor from the engine control
Page 836
value.
new one.
Page 2987
on actual vehicles.
Wire Color Codes
Locations
Hydraulic Assembly: Locations
COMPONENT VIEW
Hydraulic Unit (built-in A
Solenoid Valve)
Specifications
Malfunction Lamp / Indicator: Specifications
Supplemental restraint system warning light
..............................................................................................................................................................
1.12 W
Page 4461
Page 1360
Crankshaft: Service and Repair
REPLACEMENT
Refer to the illustration for the service procedures, noting the following: 1. When the crankshaft
bearing needs replacing, select and install a proper bearing as follows:
Page 2936
Page 4195
Standard value:
New (with anti-rust agent): 0.6 - 0.9 Nm (5.2 - 7.8 inch lbs.) New/reused (gear oil applied): 0.4 - 0.5
Nm (3.5 - 4.3 inch lbs.)
4. If the drive pinion rotation torque is not within the standard value range, adjust the rotation torque
by replacing the drive pinion front
shim(s) or the drive pinion spacer.
NOTE: When selecting the drive pinion front shims, if the number of shims is large, reduce the
number of shims to a minimum by selecting the appropriate drive pinion spacers. Also, select the
drive pinion spacer from the following two types.
Height of drive pinion spacer and identification color:
52.50 mm (2.067 inch): Yellow. 52.84 mm (2.080 inch): Red.
5. Remove the companion flange and drive pinion again.
With Oil Seal
1. After setting the drive pinion front bearing inner race, use the special tool to drive the oil seal into
the front lip of the gear carrier.
2. Apply a thin coat of clean multi-purpose grease to the companion flange contact surfaces of the
washer and the oil seal contacting surface
before installing the drive pinion assembly.

NOTE: -
(A1 - Ground)
(A2 - 88)
Page 4923
Parking Brake Shoe: Testing and Inspection
1. Remove the rear brake assembly and secure it with wire. 2. Remove the brake drum. 3.
Measure the wear of the brake lining at the place worn the most. The standard value is 6.5 mm
(0.256 inch). The limit is 4.5 mm (0.177 inch).
Replace the shoe and lining assembly if brake lining thickness is less than the limit if it is not worn
evenly.
CAUTION: -
Whenever the shoe and lining assembly is replaced, replace both RH and LH assemblies as a set
to prevent the vehicle from pulling to one side when braking.
- If there is a significant difference in the thicknesses of the shoe and lining assemblies on the left
and right sides, check the sliding condition of the piston.
Page 4762
Electronic Brake Control Module: Testing and Inspection Terminal Voltage Check
(Part 1 Of 2)
Page 1306
Lifter / Lash Adjuster: Specifications
Leak Down Time [1]
..................................................................................................................................................... 4 -
20 seconds per 1 mm (0.04 inch)
[1]: With diesel fuel temperature at 15 - 20° C (50 - 68° F)

Page 2086
OPERATION
Page 6102
Page 5858
1997 Montero Sport, Volume 2, page 52B-4, and 1997 Montero Sport Technical Information
Manual, page 6-12
Page 3969
Ignition switch-ST
HARNESS INSPECTION
module. -
NOTE: -

Page 3170


Page 2004


Page 396
Wire Color Codes
the marking color.

Specifications
Wheels: Specifications
Runout Limit:
Lateral ..................................................................................................................................................
........................... 1.0 mm (.04 inch) or less Radial ..............................................................................
............................................................................................... 1.0 mm (.04 inch) or less
Page 52
CONTROL UNIT VIEW
ABS Control Unit H
Page 2692
CONTROL UNIT VIEW
Page 6608
on actual vehicles.
Wire Color Codes
Page 6924
Dome Lamp: Testing and Inspection
1. When the doors are opened, the dome light or cargo space light does not illuminate for certain
doors,
- Check the front or rear door switch.
- Check the back door switch.
2. When the dome light switch or cargo space light switch is set to the DOOR position and any of
the doors are opened, the dome light or cargo
space light does not illuminate. a. Illuminates when the switch is at the ON position.
- Check the dome light switch or cargo space light switch.
b. It does not illuminate even if the switch is at the ON position.
- Check the light bulb.

Page 3410
1996 Montero, 3.0L 12 Valve Engine (SOHC)

Lock-Up Solenoid
Shift Solenoid: Testing and Inspection Lock-Up Solenoid
INSPECTION
1. Disconnect the lock-up solenoid connector. 2. Measure the resistance between terminal No. 8
and the ground.
Specifications
Parking Lamp: Specifications
Front Parking light ...............................................................................................................................
........................................................... 27/8 (1157) W
NOTE : The values in the parentheses denote SAE grade numbers.

Page 2286
on actual vehicles.
Wire Color Codes
Page 2256
Page 1796

Page 1956
Wire Color Codes
the marking color.

Page 2621
Wire Color Codes
the marking color.

Overhaul
Brake Caliper: Service and Repair Overhaul
Front
Page 2191
Grounding Markings

Page 3804
Automatic Transmission Overhaul Service Manual, Page 23F-58: Change the forward clutch piston
stroke specifications as shown.
Page 5242
Alignment: Service and Repair Rear Suspension
ON-VEHICLE SERVICE
The rear suspension assembly must be free of worn, loose or damaged parts prior to measurement
of rear wheel alignment. Standard value:
Toe-in: 0 mm (O inch) Camber: 0 °
NOTE: Toe-in and camber are set at the factory and cannot be adjusted.
Alignment Charts
Alignment: Specifications Alignment Charts
Front Wheel Alignment Specifications
TOE-IN
At The Center Of Tire Tread: (3.5 ± 3.5 mm (.14 ± .14 inch) 0 to 7 mm (0 to +.28 inch) At The Rim
Of Disc Wheel: (1.8 ± 1.8 mm (.07 ± .07 inch) 0 to 3.6 mm (0 to +.14 inch) Toe-In Angle (Per
Wheel): 0° to 0° 17' Toe-Out Angle On Turn (Inner Wheel When Outer Wheel Is At 20°): 21° 56'
CAMBER .............................................................................................................................................
................................. (0° 40' ± 30') -1° 10' to -0° 10'
(Left/Right Deviation Within 30')
CASTER ..............................................................................................................................................
............................... (3° 00' ± 1° 00') 4° 00' to 2° 00'
KINGPIN INCLINATION ......................................................................................................................

................................................................. 14° 52'
SIDE SLIP: (0 ± 3 mm (0 ± .12 inch)) -3 mm to +3 mm (-.12 to +.12 inch)
STEERING ANGLE
Inner Wheel .........................................................................................................................................

................................................... 29° 40' to 32° 40' Outer Wheel ........................................................
.................................................................................................................................................... 29°
45'
Rear Wheel Alignment Specifications
Toe-In ..................................................................................................................................................
............................ 0 mm (0 inch) (Non-adjustable)
Camber ................................................................................................................................................
.............................................. 0° (Non-adjustable)
Page 5219
Junction Block (J/B) (Part 2 Of 2)

Page 5095
Neutral Safety Switch: Adjustments
1. Move the selector lever to the N position.
2. Loosen the adjusting nut of the control cable.
3. Gently pull the end of the transmission control cable in the direction of the arrow and tighten the
adjusting nut to the specified torque. 4. Check that the selector lever is in the N position. 5. Check
that each range on the transmission side operates and functions correctly for each position of the
selector lever.
Page 4449
OPERATION
Page 2548
Grounding Markings

Tire Chain - Usage
Tires: Technical Service Bulletins Tire Chain - Usage
NO.: TSB-96-31-003 REV DATE: December, 1996 MODEL: All 1997 Models
SUBJECT:
1997 TIRE CHAIN USAGE
This bulletin supercedes TSB-96-31-003, issued 12/96, to correct Montero Sport tire sizes and tire
chain usage for Galant LS and ES Premium Package
PURPOSE
This bulletin contains tire chain usage recommendations for 1997 Mitsubishi cars and sport-utility
vehicles.
Refer to the "1997 Tire Chain Usage Table" in this bulletin.
AFFECTED VEHICLES
All 1997 models
TIRE CHAIN PRECAUTIONS
All 1997 models have restricted wheel clearances. Use only tire chains known as cable chains,
which meet SAE class "S", clearance specifications. Link-type chains and other traction devices do
not meet these specifications and are not recommended.
The following vehicles cannot use tire chains:
^ Galant LS and ES with Premium Package
^ Eclipse Base, GS, GS-T and GSX
^ Tire chains cannot be used on any 3000GT with factory equipment wheels and tires. However, on
base 3000GT models, if all four original wheels and tires are replaced with 15X6JJ steel wheels
and 205165R15 tires, chains may be used only on the front wheels.
^ Do not use chains on the compact spare wheel of any vehicle. The wheel may be damaged or
cause the tire to come off the wheel.
Observe the following tire chain guidelines:
^ Use tire chains only when necessary.
^ Be sure the chains are the proper size for the tires.
^ Remove wheel covers before installing the chains.
^ Tighten chains as tightly as possible.
^ Drive under 30 mph.
^ If the chains strike the vehicle body or chassis, stop the vehicle immediately and tighten them.
NOTE TO CALIFORNIA DEALERS: Consult your legal counsel for advice regarding customer
disclosure statement for vehicles that cannot use tire chains.
1997 TIRE CHAIN USAGE TABLE

Page 2198
Throttle Position Sensor: Testing and Inspection
Hint 1: The signals of the throttle position sensor are more important fore control of the automatic
transmission than for control of the engine; shifting "impact shocks" are produced if there is a
malfunction of the throttle position sensor. Hint 2: If the voltage of the throttle position sensor is
outside the standard value, check once again after making the throttle position sensor adjustment.
In addition, if there are any indication that the fixed SAS has been moved, adjust the fixed SAS.
INSPECTION
Using Scan Tool
HARNESS INSPECTION
Throttle position sensor connector: Disconnected OK: GO TO STEP 2 NG: Repair the harnesses.
(A1 - 92)
STEP 2. Check for an open or short-circuit between the throttle position sensor and the engine
control module. -
- Engine control module connector: Disconnected
- All control module connectors, such as the ECM connector, which use throttle position sensor
output: Disconnected OK: GO TO STEP 3 NG: Repair the harnesses. (A3 - 84, A4 - 81)
Page 3735
Locations
Horn Relay: Locations

Page 2918
OPERATION
control motor.
Page 1947
Fuel Pump Relay: Locations

Page 5899
CAUTION:
Removal Steps
work.
Page 3462
OPERATION
control module.
rotation.

Resistance/Torque

Page 1988
Page 705


Page 98
Tail Lamp Relay: Testing and Inspection
Page 6054
Radio/Stereo: Electrical Diagrams
With Amplifier
Radio And Tape Player (Part 1 Of 3) (Vehicles With Amplifier)
Without Amplifier
Page 2476

SENSOR VIEW

Page 331

Page 929
Transmission Temperature Sensor/Switch: Testing and Inspection
INSPECTION
1. Disconnect the oil temperature sensor connector. 2. Measure the resistances between terminals
No. 1 - 2 of the oil temperature sensor connector and check that they match the values below.
Standard value:
Oil temperature at 25° C (77° F):
Resistance value: 10 k ohms
Resistance value: 615 ohms
3. If the resistance is outside the standard value, replace the oil temperature sensor.
Cigarette Lighter: Diagram Information and Instructions
Specifications
Thermostat Housing: Specifications
Mounting Bolts .....................................................................................................................................

................................................ 24 Nm (17 ft. lbs.)
Page 4422
on actual vehicles.
Wire Color Codes
Page 1928
Page 4496
CONTROL UNIT VIEW

Page 4351
Page 2696
Grounding Markings

Front Output Shaft
Output Shaft: Service and Repair Front Output Shaft
DISASSEMBLY
A. Ball bearing removal. (1 & 2)
ASSEMBLY
A. Ball bearing installation. (1 & 2)

Page 679

Page 3574
on actual vehicles.
Wire Color Codes
Page 2957
on actual vehicles.
Wire Color Codes
Page 2147
Oxygen Sensor: Testing and Inspection Federal
Hint 1: The exhaust gas purification performance will worsen it there is a malfunction of the heated
oxygen sensor. Hint 2: If the heated oxygen sensor output voltage is outside the standard value
even though the results of the checking of the heated oxygen sensor are normal, the cause is
probably a malfunction of a component related to mixture control. [Examples] (1) Malfunction of
injector (2) Air is drawn into the intake manifold from a leaking gasket, etc. (3) Malfunction of
volume air flow sensor, intake air temperature sensor, barometric pressure sensor or engine
coolant temperature sensor
HARNESS INSPECTION
STEP 1. Check for continuity between the heated oxygen sensor and the MFI relay. -
- Heated oxygen sensor connector: Disconnected
NOTE: -
OK: GO TO STEP 2 NG: Repair the harness. (A1 - C1, B1 - C1)

Page 4525
A. Inner synchronizer ring installation. (6)
1. Apply gear oil to the synchronizer ring cone surface before installation.
B. Outer synchronizer ring installation. (4)

1. Apply gear oil to the synchronizer ring cone surface before installation.
C. Snap ring installation. (1)
1. Select and install the snap ring which adjusts the 2-4WD synchronizer hub end play to the
standard value.
Standard value: 0 - 0.08 mm (0 - 0.0031 inch)

Page 7171
4. Insert the leaded end of the lowering wire into the wire hole on the bottom surface of the drum.
Make sure that the wire is wound on the first groove of the drum without any looseness from the
underside of the drum.
5. Wind the lifting wire onto the drum.
a. Insert the top end of the lifting wire in the wire hole on the top surface of the drum.
b. Raise the forward part of the drum to its upright position and put the lifting wire into the last
groove in the drum.
c. Place the drum in its original position making sure to hold the drum so the wire does not come
off.
Note:
For assembling the power window motor and regulator after the drum and wire assembly is
complete, refer to the POWER WINDOW MOTOR AND REGULATOR ASSEMBLY section at the
beginning of this bulletin.
6. Cut off the wires that have been used to compress the spring.
PARTS INFORMATION
Page 1024
b. Line up the timing marks of the front bank camshaft sprockets. c. Line up the timing marks of the
rear bank camshaft sprockets.
CAUTION: Since the camshaft sprocket readily turns because of spring action, use care to make
sure that your finger is not caught.
d. Line up the timing marks of the crankshaft sprockets. e. Install the timing belt on each sprocket
in the following sequence:
1. Install the timing belt on the crankshaft sprocket and then on the idler pulley, while tightening it to
prevent slackness. 2. Install the timing belt on the front bank camshaft sprocket. 3. Install the timing
belt on the water pump pulley, while taking up the slack. 4. Install the timing belt on the rear bank
camshaft sprocket. 5. Install the timing belt on the tensioner pulley.
6. Lightly press the tensioner pulley against the belt and temporarily tighten the center bolt. 7.
Check to see that the timing marks of all the sprockets are in alignment.
Page 1296
6. Remove the lash adjuster from container B. Then gently push down the steel ball and push the
plunger to remove the diesel fuel from its pressure chamber.
7. Place the lash adjuster in container C. Then gently push down the internal steel ball using a stiff
wire (0.5 mm).
Do not use container C for cleaning. Foreign matter could enter the pressure chamber.
8. Stand the lash adjuster upright with its plunger at the top, then push the plunger downward firmly
until it moves through its furthest possible stroke. Return the plunger slowly, then release the steel
ball and allow the pressure chamber to fill with diesel fuel.
9. Remove the lash adjuster from container C and stand it upright with its plunger at the top. Push
the plunger firmly and check that it does not move.
If the lash adjuster contracts, repeat Steps 7 through 9 to fill it completely with diesel fuel. If it
contracts again, replace it.
10. Stand the lash adjuster upright to prevent the diesel fuel from spilling out. Do not allow it to
become contaminated by dirt or other foreign substances. Install it in the engine as soon as
possible.
Standard warranty procedures apply. Use the appropriate "Auto Lash Adjuster Cleaning" labor
operation code.
ABS Main Relay: Testing and Inspection
ABS RELAY BOX (WITH BUILT-IN MOTOR RELAY AND VALVE RELAY)
1. Disconnect the ABS relay box connector. 2. Check the continuity between the terminals of the
ABS relay (box-side) connector when current is flowing. 3. Repeat Step 2 when current is not
flowing. 4. Refer to the illustration for terminal layout and specifications.
Page 6168
Side garnish: 20-30 degrees C (68- 86 degrees F)
4. Firmly press in the side garnish
BACK DOOR GARNISH AND LICENSE PLATE GARNISH

INSTALLATION OF BACK DOOR GARNISH AND LICENSE PLATE GARNISH
Page 3905
NOTE: -
CAUTION: -

Service and Repair
Heated Glass Control Module: Service and Repair

Page 6427
Cruise Control Vacuum Solenoid: Testing and Inspection
Solenoid valve (Control valve, Release valve)
1. Disconnect the cruise vacuum pump connector. 2. Measure the resistance between terminals (1)
- (2) and between (I) - (3).
Standard value: 50 - 60 Ohms
3. Check that the solenoid valve makes an operating noise when battery positive voltage is applied
between terminals (1) - (2) and between (1) - (3). 4. If there is a malfunction of the solenoid valve,
replace the cruise vacuum pump assembly.
Motor
1. Disconnect the cruise vacuum pump connector. 2. Check that the motor operates when battery
positive voltage is applied between terminals (1) - (4).
Page 2425

Locations
Auxiliary Power Outlet: Locations

Page 2836
Grounding Markings

Page 6221
B. CAUTION: SRS
Read service manual. Do not drop. Do not tamper or disassemble.
C. WARNING TO AVOID SERIOUS INJURY
- For maximum safety protection in all types of crashes. You must always wear your safety belt.
- Do not install rearward-facing child seats in any passenger seat position.
- Do not sit or lean unnecessarily close to the air bag.
- Do not place any objects over the air bag or between the air bag and yourself.
- See the owner's manual for further information and explanations.
D. AIR BAG SYSTEM INFORMATION
This vehicle has an air bag system which will supplement the seatbelt in certain frontal collisions.
The air bag is not a substitute for the seatbelt in any type of collision. The driver and all other
occupants should wear seatbelts at all times.
WARNING: If the "SRS" warning light does not illuminate for several seconds when the ignition key
is turned to "ON" or the engine is started, or if the warning light stays on while driving, take the
vehicle to your nearest authorized dealer immediately. Also, if the vehicle's front end is damaged or
if the air bag has deployed, take the vehicle for service immediately.
The air bag system must be inspected by an authorized dealer ten years after the vehicle
manufacture date shown on the certification label located on the left front door latch post or door
frame.
Read the "SRS" section of your owner's manual before driving for important information about
operation and service of the air bag system.
When you are going to discard your gas generator or vehicle, please see your dealer.
E. CAUTION: Do not disassemble or drop. If defect refer to service manual.
F. CAUTION: SRS
Before replacing steering wheel, read service manual, center front wheels and align SRS clock
spring neutral marks.
Failure to do so may render SRS system inoperative, risking serious driver injury.
G. WARNING: SRS
This air bag module cannot be repaired. Do not disassemble or tamper.
Do not perform diagnosis. Do not touch with electrical test equipment or probes. Refer to service
manual for further instructions, and for special handling, storage and disposal procedures.
Tampering or mishandling can result in injury.
H. Danger: Poison.
keep out of the reach of children. Contains sodium azide and potassium nitrate contents are
poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce
harmful and irritating gases or explosive compounds. Do not dismantle, incinerate, bring into
contact with electricity or store at temperatures exceeding 200 °F.
First aid: If contents are swallowed induce vomiting. For eye contact flush eye with water for 15
minutes. If gases from acid or water contact are inhaled, seek fresh air. In every case, get prompt
medical attention.
For additional information, see material safety data sheet (MSDS) for this product.
I. CAUTION: SRS clock spring
This is not a repairable part.
If defective, replace entire unit per service manual instructions.
To recenter rotate clockwise until tight.
Then rotate in opposite direction approximately 3 1/3 turns and align.
J. CAUTION: SRS
Before removal of steering gearbox, read service manual, center front wheels and remove ignition
key.
Fuel Gauge Unit
Float Point "F" ......................................................................................................................................

................................................................ 3 ± 2 Ohm Float Point "E" ..................................................
................................................................................................................................................ 110 ± 7
Ohm
Page 265
Heated Glass Element Relay: Testing and Inspection
1. Remove the instrument under cover. 2. Remove the defogger timer from the relay bracket. 3.
Connect the battery and the test light to the timer as shown in the illustration. 4. Check that the test
light illuminates for approximately eleven seconds when battery positive voltage is applied to
terminal (3) for a few seconds. 5. Check that the test light switches off when battery positive
voltage is again applied to terminal (3) during the test described above.
Defogger Relay
Defogger Relay - Chart
1. Remove the instrument under cover. 2. Remove the defogger relay from the relay bracket. 3.
Page 5518
Suspension Control Module: Service and Repair
Pre-removal and Post-installation Operation. -
Quarter Trim Lower Removal and Installation.

Page 2394
Compression Check: Testing and Inspection
1. Before inspection, check that the engine oil, starter and battery are in good condition. Also, set
the vehicle to the following conditions:
- Transmission: P range.
2. Disconnect the spark plug cables. 3. Remove all of the spark plugs. 4. Disconnect the crankshaft
position sensor connector.
NOTE: Doing this will prevent the engine control module from carrying out ignition and fuel
injection.
5. Cover the spark plug hole with a rag, and after the engine has been cranked, check that no
foreign material is adhering to the rag.
CAUTION: -
Keep away from the spark plug hole when cranking.
- Do not let water, oil, fuel, etc. enter the cylinder through cracks, or these heated materials will
gush out from the spark plug hole, which is dangerous.
6. Install the compression gauge into a spark plug hole. 7. Crank the engine with the throttle valve
fully open and measure the compression pressure.
Standard value: 1200 kPa (171 psi) @ 250 - 400 RPM Limit: 890 kPa (127 psi) @ 250 - 400 RPM
8. Measure the compression of all the cylinders, and check that the pressure differences of the
cylinders are below the limit. The (maximum) limit is
100 kPa (14 psi).
9. If there is a cylinder with compression or a compression difference that is outside the limit, pour
a small amount of engine oil through the spark
plug hole, and repeat the operations in steps 6 to 8.
NOTE: -
If the compression increases after oil is added, the cause of the malfunction is a worn or damaged
piston ring and/or cylinder inner surface.
- If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or
pressure leaking from the gasket.
10. Reconnect the crankshaft position sensor connector. 11. Reinstall the spark plugs and spark
plug cables. 12. Use the scan tool to erase the diagnostic trouble codes, or disconnect the negative
battery cable for 10 seconds or more and then re-connect it.
NOTE: This will erase the diagnostic trouble code resulting from the crankshaft position sensor
connector being disconnected.
Page 652
Page 3781
REMOVAL
INSTALLATION
Page 6053
Wire Color Codes
the marking color.

Page 5941
Failure to do so may damage SRS clock spring and render SRS system inoperative, risking serious
driver injury.
Page 780
position sensor.

Page 4684

Page 1659
Timing Belt Tensioner: Testing and Inspection
TENSIONER
Turn the pulley. If it rotates roughly, develops noise or excessive play, replace the timing belt
tensioner.
AUTO TENSIONER
1. Check for oil leaks. If oil leaks are evident, replace the auto tensioner. 2. Check the rod end for
wear or damage and replace the auto tensioner if necessary.
3. Measure the rod projection length. If the reading is outside the standard value, replace the auto
tensioner. The standard value is 11.7 - 12.3 mm
(0.461 - 0.484 inch).
4. Press the rod with a force of 98 to 196 N (22 to 44 lbs.) and measure the movement of rod. If the
measured value is out of the standard value,
replace the auto tensioner. The standard value is 1 mm (0.0393 inch) or less.
Page 6668
Oil Pressure Warning Lamp/Indicator: Electrical Diagrams

Page 6620

Page 5249

Page 2851
Grounding Markings

Diagrams
Page 2823
on actual vehicles.
Wire Color Codes
Specifications
Headlamp Dimmer Switch: Specifications
Rated load ...........................................................................................................................................
........................................................... High beam : 12 ........................................................................
............................................................................................................................................. Low
beam : 10.8 ..........................................................................................................................................
...................................................................... Passing : 22.8 ± 1.5 Voltage drop ................................
..............................................................................................................................................................
........ 0.2 V or less
Page 4391
Part 3 Of 3
Page 3491
Page 136
Wire Color Codes
the marking color.

Page 4334
NOTE:
Page 5616
Wheels: Application and ID
GENERAL INFORMATION
Wheel Type: Aluminum type. Size: 15 x 7JJ. Amount of wheel offset: 10 mm (.39 inch). Pitch Circle
Diameter (P.C.D.): 139.7 mm (5.5 inch).
Page 2285


Page 4848
shown.
INSPECTION
Page 496
Page 854
Neutral Safety Switch: Specifications
Bolt ......................................................................................................................................................
...................................... 13 Nm (108 inch lbs.) Nut .............................................................................
................................................................................................................. 4 Nm (34.8 inch lbs.)
Page 3103
Leak Detection Solenoid: Description and Operation
OPERATION
- The evaporative emission ventilation solenoid is a ON - OFF type solenoid valve and installed to
monitor the leak in the fuel tank and purge line. Normally it opens the atmospheric release opening
and closes during the leak monitoring.
- Through the MFI relay the battery power is supplied to the evaporative emission ventilation
solenoid. If the ECM switches on the power transistor in the module, the current flows in the coil
and close the EVAP canister atmospheric release opening.

Switch Adjustment
V4AW2 A/T.
23A-45
Page 4041
Torque Converter: Testing and Inspection
CONVERTER STALL TEST
NOTE: In this test, the engine maximum speed when the torque converter stalls with the shift lever
in the D or R position is measured to check operation of the torque converter, stator and one-way
clutch and check holding performance of the transmission clutch (including brake).
CAUTION: Do not stand in front or at rear of the vehicle during this test.
1. Check the transmission fluid level. The fluid temperature should be at the level after normal
operation [50-80° C (122-176° F)]. The engine
coolant temperature should also be at the level after normal operation [80-90° C (176-1 94° F)].
2. Apply.chocks to the rear wheels (right and left). 3. Connect a tachometer. 4. Apply the parking
and service brakes fully. 5. Start the engine. 6. With the selector lever in the D position, fully
depress the accelerator pedal and take a reading of the engine maximum speed.
Standard value: 2,100-2,600 rpm
NOTE: When doing so, do not keep the engine running with the throttle fully open for longer than
necessary (5 seconds or more). If two or more stall tests are needed, move the selector lever to the
N position and run it at idle for at about 1,000 rpm to allow the transmission fluid to cool before
another stall test.
7. Move the selector lever to the R position and perform the test as above.
JUDGEMENT OF STALL TEST RESULTS

Page 2104
STEP 3. Measure the power supply voltage. -
*INTAKE AIR TEMPERATURE CHECK
(1) Disconnect the volume air flow sensor connectors. (2) Measure the resistance between terminal
(5) and terminal (6).
Standard value:
(3) Measure the resistance while heating the sensor using a hair drier.
(4) If resistance does not decrease as heat increases or the resistance remains unchanged,
replace the volume air flow sensor assembly.
Page 3041

Page 3028


Page 5068
16. Turn the ignition switch to the OFF position. 17. Disconnect the negative battery cable. 18.
Disconnect the ammeter, voltmeter and tachometer. 19. Connect the generator output wire to the
generator "B" terminal. 20. Connect the negative battery cable.
Page 683
on actual vehicles.
Wire Color Codes
Locations
Headlamp Relay: Locations

Page 3456
Grounding Markings

Page 650
on actual vehicles.
Wire Color Codes
Page 898
Grounding Markings

Page 3133
EGR Valve: Testing and Inspection
1. Remove the EGR valve and check it for sticking, deposit of carbon, etc.
If such condition exists, clean with adequate solvent to ensure tight valve seat contact.
2. Connect a hand vacuum pump to EGR valve. 3. Apply a vacuum of 67 kPa (19.7 in.Hg.) and
check airtightness.
4. Blow in air from one passage of the EGR to check condition as follows. 5. Install a new gasket
and EGR valve, tighten bolts to specified torque.
Specified tightening torque: 22 Nm (16 ft.lbs.)

Specifications
Standard ..............................................................................................................................................
....................................................................................................................... 890 kPa (127 psi)
.................................................................................................................................................. 100
kPa (14 psi)
Page 2333
increased.

Air Flow Meter/Sensor: Component Tests and General Diagnostics
Hint 1: If the engine sometimes stalls, try starting the engine and shaking the volume air flow
sensor harness. It the engine then stalls, incorrect or improper contact of the volume air flow
sensor connector is the probable cause. Hint 2: If the volume air flow sensor output frequency is
any value other than zero when the ignition switch is switched ON (but the engine is not started), a
malfunction of the volume air flow sensor or of the engine control module is the probable cause.
Hint 3: If idling is possible even though the volume air flow sensor output frequency is outside the
standard value, the cause is usually a malfunction other than of the volume air flow sensor.
[Examples] (1) The flow of air within the volume air flow sensor is disturbed. (Air duct disconnection
or clogged air cleaner element.) (2) Incomplete combustion inside a cylinder (Malfunction of spark
plugs, ignition coil, injectors, compression pressure, etc.) (3) Air is drawn into the intake manifold
through a leaking gasket, etc.
NOTE: When the vehicle is new [driven approximately 500 km (300 miles) or less], the volume air
flow sensor output frequency may be approximately 10% higher than indicated above.
Page 2035
Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Sensor

Resistance/Torque
Design Thermistor

Dashpot: Testing and Inspection

1. Inspect the idle speed before inspection and adjustment of the dashpot. 2. Set the vehicle in the
following conditions before dashpot inspection and adjustment.
- Engine coolant temperature: 80 - 95° C (176 - 203° F)
- Lights and accessories: "OFF"
- Transmission: Neutral (P for A/T)
3. Connect the scan tool to the data link connector. 4. Start the engine. 5. Open the throttle valve
until the dashpot rod makes a full stroke. 6. Close the throttle valve slowly to find a point where the
throttle lever contacts the dashpot rod (a point where the dashpot starts to contract). Hold
the throttle valve at this point.
7. Check the engine speed (at which the dashpot starts to operate).
Standard value: 2,000 - 2400 RPM.
8. If the engine speed is not within the specified limit, loosen the lock nut on the rod and turn the
rod to make adjustment for proper dashpot starting
engine speed.
9. Release the throttle valve to make sure that the engine speed slowly drops to the idle speed.
Page 449
Basic Idle Speed
Idle Speed: Adjustments Basic Idle Speed
NOTE: (1) The standard idling speed has been adjusted, by the speed adjusting screw (SAS), by
the manufacturer, and there should usually be no need for
readjustment.
(2) If the adjustment has been changed by mistake, the idle speed may become too high or the idle
speed may drop too low when loads from
components such as the A/C are placed on the engine. If this occurs, adjust by the following
procedure.
(3) The adjustment, if made, should be made after first confirming that the spark plugs, the
injectors, the idle air control motor, the compression
pressure, etc., are all normal.
1. The vehicle should be prepared as follows before the inspection and adjustment.
- Engine coolant temperature: 80 - 95°C (176 - 203°F)
- Lights and accessories: OFF
- Transmission: Neutral (A/T for P range)
2. Connect the scan tool to the data link connector (16-pin).
NOTE: When the scan tool is connected, the diagnostic test mode control terminal should be
grounded.
3. Start the engine and run at idle. 4. Select the item No.30 of the scan tool Actuator test.
NOTE: This holds the IAC motor at the basic step to adjust the basic idle speed.
5. Check the idle speed.
Standard value: 700 ± 50 r/min

NOTE: (1) The engine speed may be 20 to 100 r/min lower than indicated above for a new vehicle
[driven approximately 500 km (300 mile) or less], but
no adjustment is necessary.
(2) If the engine stalls or the engine speed is low even though the vehicle has been driven
approximately 500 km (300 mile) or more, it is probable
that deposits are adhered to the throttle valve, so clean it.
6. If not within the standard value range, turn the speed adjusting screw (SAS) to make the
necessary adjustment.
NOTE: If the idling speed is higher than the standard value range even when the SAS is fully
closed, check whether or not there is any indication that the fixed SAS has been moved. If there is
an indication that it has been moved, adjust the fixed SAS.
7. Press the scan tool clear key, and release the AC motor Actuator test mode.
NOTE: Unless the AC motor is released, the Actuator test mode will continue 27 minutes.
8. Switch OFF the ignition switch. 9. Disconnect the scan tool.
10. Start the engine again and let it run at idle speed for about 10 minutes; check that the idling
condition is normal.
Page 4052
A. Hose E/hose D/return pipe B/feed pipe B installation. (12, 13, 14 & 15)
When connecting hoses to pipes with a stepped part, insert securely as far as the stepped part.
B. Return pipe A/feed pipe A/clamp installation. (4, 5 & 6)
1. Provisionally tighten the return pipe A and feed pipe A flare nuts to the transmission and transfer,
and after clamping the pipes with each
clamp, fully tighten the flare nuts. Also, tighten all of the clamps, starting with those that are the
closest to the transmission and transfer assembly.
2. When connecting the pipes to the hoses, insert securely as far as the stepped part.
C. Hose C/hose B/hose A installation. (1, 2 & 3)
When connecting the pipes to the hoses, insert securely as far as the stepped part.
NOTE: Operational steps after installation as follows:
1. Fill and bleed automatic transmission fluid. 2. Install under cover and under skid plate.
Page 3936
First & Reverse Brake Disc
1. Using a micrometer, measure the thickness of the brake disc.
Limit: 1.51 mm (0.0594 inch)
the limit.
ASSEMBLY
A. First & reverse brake piston No. 1 / reverse brake sleeve installation. (23 & 25)
1. Install the first & reverse brake piston No. 1 and the reverse brake sleeve together to the
transmission case.
B. First & reverse brake piston No. 2 installation. (21)
1. Aligning the convex of the first & reverse brake piston No. 2 with the concave of the transmission
case, install the piston to the case.
Page 397

Page 2273
pushed.

malfunction.
Page 1756
Component View
Volt Meter Gauge: Diagram Information and Instructions
Page 3261

Page 6561
Fuel Gauge: Specifications Fuel Gage Resistance
Power supply and ground ....................................................................................................................
......................................................... 115 ± 11.5 Ohm Power supply and fuel gage ...........................
................................................................................................................................................... 79 ±
7.9 Ohm Fuel gage and ground ...........................................................................................................
............................................................................ 80 ± 8.0 Ohm
NOTE: -
(A1 - Ground)
(A2 - 88)
Page 206
RELAY VIEW
Starter Relay E
Page 4876
NOTE:

Page 530

Page 5886
Air Bag: Removal and Replacement
CAUTION:
1. Never attempt to disassemble or repair the air bag module or clock spring. If faulty, replace it.
Do not drop the air bag module or clock spring or allow contact with water, grease or oil. Replace it
if a dent, crack, deformation or rust are detected.
2. The air bag module should be stored on a flat surface and placed so that the pad surface is
facing upward.
Do not place anything on top of the air bag modules.
4. Do not expose the air bag module to temperature over 93°C (200°F). 5. After deployment of an
air bag, replace the clock spring with a new one. 6. Wear gloves and safety glasses when handling
an air bag that has deployed. 7. An undeployed air bag module should only be disposed of in
accordance with the procedures.
- After setting the steering wheel and the front wheels, to the straight ahead position, remove the
ignition key.
Air Bag Module And Clock Spring
Clock Spring Removal Steps
1. Negative (-) battery cable connection 2. Air bag module (Driver's side) 3. Cap 4. Steering wheel
5. Column cover lower 6. Clock spring and body wiring harness connection 7. Clock spring -
Pre-installation
Air Bag Module Removal Steps (Driver's side)
1. Negative (-) battery cable connection 2. Air bag module (Driver's side) -
Pre-installation inspection
Air Bag Module (Passenger's side)

Service and Repair
Blower Motor: Service and Repair

Page 2486
OPERATION
engine is cold.
Page 5822
Component View
Alternator
Drive Belt: Adjustments Alternator
Page 3248
Point A: Height of injector coil induced voltage
Point B: Injector drive time -
The injector drive timing will synchronized with the scan tool display.
- When the engine is suddenly raced, the drive time will be greatly extended at first, but the drive
time will soon match the engine speed.
Page 625


Page 4080
Page 2724

Page 4485
INSPECTION
transfer case.
transfer case.
transfer case.

Specifications
............................................................... 1.4 (74) W

Page 6147
Locations

Page 7014


Page 557
increased.

Page 619
SENSOR VIEW
Left Bank Heated Oxygen Sensor (front) Y
Left Bank Heated Oxygen Sensor (rear) X

Page 3533
Ignition Coil: Description and Operation
OPERATION
- When the ignition power transistor unit A is turned on by the signal from the engine control
module, primary current flows to the ignition coil A. When the ignition power transistor unit A is
turned off, the primary current is shut off and a high voltage is induced in the secondary coil A,
causing the ignition plugs of No. 1 and No. 4 cylinders to spark. When the ignition power transistor
unit B is turned off, the ignition plugs of No. 2 and No. 5 cylinder spark. In addition, when the
ignition power transistor unit C is turned off, the ignition plugs of No. 3 and No. 6 cylinders spark.
- When the engine control module turns off the transistor in the unit, the battery positive voltage in
the unit is applied to the ignition power transistor unit to turn it on. When the engine control module
turns on the transistor in the unit, the ignition power transistor unit is turned off.
Specifications
Rated load ...........................................................................................................................................
............................................................... 6.6 ± 0.05 A Voltage drop ....................................................
.................................................................................................................................................. 0.2 V
or less
Page 3038
SENSOR VIEW

Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions
Page 5360
driver injury.
Page 2709
Page 2893

Page 2603
Examples of abnormal wave patterns Cause of problem Malfunction of motor (Motor is not
operating)
Induced voltage from the motor turning does not appear.

Lower Arm Bushing (A) Replacement
Control Arm Bushing: Service and Repair Lower Arm Bushing (A) Replacement
1. Using the special tool, remove the bushing A from the bracket.
NOTE: When removing the left hand bushing A detach the differential carrier.
2. Using the special tool, press-fit the bushing A into the bracket.
NOTE: Bushing (A) should be installed so that it faces as shown in the illustration.
Page 4126
17. Install the throttle valve to the valve body as illustrated.
18. Install the valve vibrating stopper in the illustrated position.
19. With the valve vibrating stopper held with a finger, turn the valve body over. Install the E-rings
to the throttle valve.
CAUTION: The number of E-rings to be installed must be equal to that of the E-rings which were
removed.
20. Install the spring to the throttle valve.
21. Turn the valve body over again. Install the spring and downshift valve as illustrated. 22. While
pushing the downshift valve with a finger, install the pin.
Page 3119
Wire Color Codes
the marking color.

Page 2457


Page 6091
Tape Player: Electrical Diagrams
With Amplifier
Radio And Tape Player (Part 1 Of 3) (Vehicles With Amplifier)
Without Amplifier
Capacity Specifications
Refrigerant: Capacity Specifications CAPACITY
CAPACITY
Total System Capacity
594-653 Grams 1.31-1.44 Lbs.(US)

..................................................................................................................................... 145 ± 14.5
ground ..............................................................................................................................................
246 ± 24.6 Ohm
Page 2509

Page 3849
Limit: 1.51 mm (0.0594 inch)
the limit.
ASSEMBLY
transmission case.
Locations
Compressor Clutch Relay: Locations

Page 2619


Specifications
Valve Seat: Specifications
DIMENSIONS
Oversize Ring Hole Diameters
Intake Seat:
0.3 O.S.
................................................................................................................................................. 34.30 -
34.33 mm (1.3504 - 1.3516 inch) 0.6 O.S.
................................................................................................................................................. 34.60 -
34.63 mm (1.3622 - 1.3634 inch)
Exhaust Seat:
0.3 O.S.
................................................................................................................................................. 31.80 -
31.83 mm (1.2520 - 1.2531 inch) 0.6 O.S.
................................................................................................................................................. 32.10 -
32.13 mm (1.2638 - 1.2650 inch)
Valve Contact Width

..................................................................................................................................................... 0.9 -
1.3 mm (0.035 - 0.051 inch)
Page 1806
Page 3790
INSPECTION
the ground.
Page 2645
Oxygen Sensor: Electrical Diagrams
Page 1919
Grounding Markings

Page 6588

Page 4096
INSPECTION
Standard value:
Page 3026
Grounding Markings

Page 6285
There are numerous brands available for repairing paint damage. Listed are a few examples:
NOTE:
Use only one (1) manufacturer's system. Do not mix products.
Repair Procedures
The goal in correcting paint damage is to repair it, not to cover it up. This means removing only a
thin part of topcoat that is damaged. The maximum amount of topcoat that can safely be removed
is 0.5 mil, (.0005"). That's the MAXIMUM. Clearcoat thickness is approximately 0.8-1.5 mils. If you
remove too much of the clearcoat, this will leave a dark spot or a haze in the paint which cannot be
repaired by buffing.
The following general instructions should be used to repair any paint damage. See minor, major
and rail dust repair information for additional instructions.
General Instructions
1) Wash the vehicle to remove loose dirt. Remove any road tar with a silicone wax & tar remover.
Dry the vehicle with soft cotton towels. A chamois is not recommended - as it may hold dirt and
scratch the paint surface.
2) Inspect the paint finish, preferably under fluorescent light and in natural light, to identify any paint
damage.
3) All repairs should be done out of direct sunlight and the vehicle1s surface should be allowed to
cool down before starting.
4) When attempting to repair, do not remove more than 0.5 mil of the topcoat. That's the safety
margin.
5) A variable speed rotary buffer is recommended (1200-1800 RPM).
6) Start by buffing a small section two feet by two feet. We recommend using foam pads rather
than wool pads.
7) Avoid buffing edges or character lines where the paint is thinner.
8) Use a small amount of product on the pad. Too much cleaner will load up the pad and waste
material.
9) Do not buff dry any cleaner on the paint surface.
10) Use a soft cotton towel to wipe off all remaining product.
11) Use only light pressure and the weight of the machine during buffing. Keep the pad flat on the
surface. Allow the cleaner to do the work.
Minor Damage Repair
1) Measure the paint thickness with a mil gauge and record the measurements on a sheet of paper.
These measurements will help you to track the amount of paint removed.
2) Start buffing the affected areas by using the least aggressive cutting pad and least aggressive
cleaner. Repeat this step if necessary. (Remember to re-measure the paint thickness after buffing.)
Page 5701
Page 7181
motor to the square hole in the drum.
Note:
^ For regulator motor and regulator phase alignment, slide the glass bracket (glass mount) to a
distance of 12.7mm or rotate the drum with a ratchet wrench handle to achieve the same
movement of the bracket.
^ Rotation of the drum may cause the wire to come off the drum. To prevent this, hold the drum
and guide with your hands.
4. Align the guide and the motor housing opening. While holding the guide and the drum, let it slide
into the motor housing.
Note:
To prevent drum runout, bend the lugs so the metallic cover is not loose. If the drum has runout,
the glass may not lower or lift smoothly (example: may rattle when lowering).
5. Align the metallic cover lug with the metallic cover mounting hole. Be sure to bend the lugs to
secure the cover to the housing.
Note:
When replacing the regulator assembly (service part), use a new metallic cover that is in the set.
When replacing only the motor, reuse the removed metallic cover.
6. Apply battery voltage to the power window motor to make sure the glass bracket moves
smoothly.
DRUM AND REGULATOR WIRE ASSEMBLY

Specifications
Radiator Cap: Specifications
Opening Pressure
High Pressure Valve:
Standard ..............................................................................................................................................
................................ 75 - 105 kPa (11 - 15 psi) Limit ..........................................................................
......................................................................................................................... 65 kPa (9.2 psi)
Vacuum Valve .....................................................................................................................................

............................. -5 kPa or less (-0.7 kPa or less)
Federal
OPERATION
Page 690
harnesses.
Page 772
Grounding Markings

M/T - Revised Clutch Interlock Switch Service Precaution
Clutch Switch: Technical Service Bulletins M/T - Revised Clutch Interlock Switch Service
Precaution
SUBJECT: CAUTIONARY INSTRUCTION FOR HANDLING CLUTCH INTERLOCK SWITCHES -
PURPOSE
Cautionary instructions for handling the clutch interlock switch are being added to the applicable
sections of the Service Manuals for all affected vehicles. This TSB advises the added information.
AFFECTED VEHICLES
All models equipped with manual transmission except Raider.

Page 4152
Solenoid: Testing and Inspection
OPERATION CHECK
1. Remove the vacuum hoses (blue stripe, yellow stripe) from the solenoid valves.
2. Disconnect the harness connectors.
3. Connect a hand vacuum pump to solenoid valve A. Apply negative pressure and carry out the
following inspections.
a. Even if the hand pump is operated with no other operation, no negative pressure develops. b.
Even when battery positive voltage is applied to solenoid A, the condition is the same as in (a). But
when the vacuum hose of solenoid B is
blocked by bending at the * mark, negative pressure is maintained.
c. When battery positive voltage is applied to solenoids A and B. negative pressure is maintained.
4. Connect the hand vacuum pump to solenoid valve B.
Apply negative pressure and carry out the following inspections. a. With no other operation,
negative pressure is maintained. b. When battery positive voltage is applied to solenoid B. the
negative pressure equalizes. c. When battery positive voltage is applied to solenoid A, the negative
pressure equalizes.
5. Measure the resistance of the solenoid valves.
Standard value: 36-46 ohms [at 20° C (68° F)]

Page 5561


Page 5906
Air Bag Module (passenger's Side)
Air Bag Module Removal Steps (Passenger's side)
1. Negative (-) battery cable connection 8. Foot shower duct (R.H) 9. Stopper
10. Glove box 11. Air bag module (Passenger's side)
- Pre-installation inspection
work.
Step 2: Air Bag Module Removal 1. Remove the air bag module mounting nut using a socket
wrench from the back side.
Page 1202
Tires: Technical Service Bulletins Tires - Goodyear(R) Product Service Locations
SUBJECT: GOODYEAR TIRE PRODUCT SERVICE LOCATIONS
PURPOSE
In the event of any issue related to Goodyear tires, customers should first contact Goodyear Tire
Company Customer Service at 1-800-321-2136.
If Goodyear Customer Service cannot resolve the customer's Concern, the nearest Goodyear
North American Product Service Field Manager as shown may be contacted.
AFFECTED VEHICLES Lancer, Diamante, Eclipse, Eclipse Spyder, and Galant models equipped
with Goodyear tires.
Page 3676
Grounding Markings

A/C - Replacement of HVAC System
Housing Assembly HVAC: Technical Service Bulletins A/C - Replacement of HVAC System
SOURCE: Mitsubishi Tech Talk Article March 2004
TITLE: REPLACEMENT OF HVAC SYSTEM
APPLIES TO: All
SERVICE TIP:
Make sure when replacing a HVAC system that ALL related parts are transferred from the old
HVAC unit to the new. There have been some reports that floor ducts have been left off the new
unit, causing complaints of poor heating or no air flow to the footwell.
Page 3414
Page 5838
B. CAUTION: SRS
frame.
F. CAUTION: SRS
G. WARNING: SRS
H. Danger: Poison.
medical attention.
J. CAUTION: SRS
key.
Page 5632
2. Drive out the inner and outer bearing outer races by tapping them uniformly. 3. Apply
multi-purpose grease to the outside surfaces of the new inner and outer bearing outer races.
4. Use the special tools to press-fit the inner and outer bearing outer races.
NOTE: The bearing inner race and bearing outer race should be replaced as an assembly.
ASSEMBLY
A. Oil seal installation. (2)
1. Apply multi-purpose grease to the lip of the oil seal and to the inside surface of the front hub. 2.
Apply multi-purpose grease to the inner bearing inner race, and then install the inner race to the
front hub. 3. Use the special tools to press-fit the new oil seal to the front hub until the oil seal is
flush with the front hub end face.
Page 2897

Page 4209
A. Screw removal. (1)
1. Loosen the screws of the differential cases (A) and (B) uniformly a little at a time. 2. Separate
differential case (A) from differential case (B). 3. Remove the components from differential case
(B).
NOTE: Keep the right and left thrust washers, spring plates, spring discs, friction plates and friction
discs separate in order to be able to distinguish them for assembly.
Inspection
CONTACT AND SLIDING SURFACES OF PARTS
1. Check the friction plate, friction disc, spring plate and pressure ring.
A. Friction surfaces of friction plate, friction disc and spring plate.
If there are any signs of seizure, severe friction or color change from the heat, it will adversely
affect the locking performance. Replace the part with a new one.
NOTE: The strong contact on the inner circumference of the friction surfaces is because of the
spring plate. This wear is not abnormal.
B. Six projections on inner circumference of friction disc If there are nicks and dents, it will cause
abnormalities in the clutch pressure.
Use an oil stone to repair the parts. If the parts cannot be repaired, replace them.
C. Four projections on outer circumference of friction disc.
If there are nicks and dents, it will cause abnormalities in the clutch pressure. Use an oil stone to
repair the parts. If the parts cannot be repaired, replace them.
D. Friction surface of pressure ring friction disc.
If there are nicks and scratches, repair the part by first grinding with an oil stone and then polishing
with rubbing compound on a surface plate.
NOTE: The strong contact on the inner circumference of the friction surface is because of the
spring plate. This wear is not abnormal.
Locations
Control Module HVAC: Locations
CONTROL UNIT VIEW
A/C Control Unit B

Drive/Propeller Shaft: Mechanical Specifications
Clearance Between Snap Ring And Groove Wall Of Yoke: 0.06 mm (0.0024 inch) or less Propeller
Shaft Runout (Limit)
...........................................................................................................................................................
0.6 mm (0.024 inch)
Page 6903
on actual vehicles.
Wire Color Codes
Page 2758
Grounding Markings

Page 279
RELAY VIEW
Intermittent Wiper Relay (Windshield Wiper) D

Locations
Hydraulic Assembly: Locations
COMPONENT VIEW
Hydraulic Unit (built-in A
Solenoid Valve)
Page 874
INSPECTION
Using Scan Tool

HARNESS INSPECTION
(A1 - 37)
control module.
Page 7065

Specifications
Center Link: Specifications
Tie Rod End Nuts ................................................................................................................................

.................................................. 44 Nm (33 ft.lbs.)
Specifications
Transmission Temperature Sensor/Switch: Specifications
Oil Temperature Sensor ......................................................................................................................

............................................ 15 Nm (11 ft. lbs.)
Page 3958
Component View
Park/Neutral Position Sensor G
Page 3645
INSPECTION
the ground.
Specifications
Crankshaft Gear/Sprocket: Specifications
Crankshaft Pulley Bolt Torque 182 Nm

Page 5966
on actual vehicles.
Wire Color Codes
Specifications
..................................................................... 1.12 W
Page 4336
NOTE:
Page 4863
Brake Bleeding: Service and Repair Without ABS
1. Start the engine and bleed the air in the sequence shown in the figure. 2. Pump the brake pedal
3-4 times. With the pedal depressed, have a helper momentarily open the first bleeder screw. Do
not release the brake pedal
until the bleeder screw is tightened.
3. Repeat 2-3 times and move on to the next bleeder screw in the illustration. 4. Repeat until all air
is purged from the hydraulic system.
CAUTION: Use the specified brake fluid. The specified brake fluid is DOT 3 or DOT 4. Avoid using
a mixture of the specified brake fluids and other fluids. When supplying brake fluid for vehicles with
ABS, the filter/strainer should be installed to the master cylinder reserve tank.
Muffler: Testing and Inspection
- Check the mufflers and pipes for corrosion or damage.
- Check the rubber hangers and rubber suspenders for deterioration or damage.
- Check for gas leakage from mufflers and pipes.

Page 4073

control module.
Page 2535
7. If the PCM has already been reprogrammed with this database, or if the MUT-III main harness is
not properly connected to the VCI unit, this message displays and reprogramming will not continue.
8. Verify that the harness is connected properly, then press ENTER. The VCI will retry
reprogramming.
Step 1: Saves data to the back-up memory.

Page 5204
on actual vehicles.
Wire Color Codes
Specifications
Rated load ...........................................................................................................................................
........................................................... High beam : 12 ........................................................................
............................................................................................................................................. Low
beam : 10.8 ..........................................................................................................................................
..............................................................................................................................................................
........ 0.2 V or less
Page 1624
6. For the right bank use seal installation tool No. MD998714, or equivalent. On the left bank, use
tool Nos. MD998714 and MD991559, or
equivalents, and press fit the oil seal into place.
7. Install the camshaft sprocket and tighten to 88 Nm (65 ft. lbs.).

Page 116
connector.
NOTE:
Page 1893
Muffler: Service and Repair California

Page 24
CONTROL UNIT VIEW
Keyless Entry Control Unit H
Page 5081
3. Check that the return spring is set to the spring stopper of the 2-4WD shift lug, and then install
the control lever in the position shown by
the arrow.
4. Apply specified adhesive to the threads of the lever assembly mounting bolts, and then tighten
the transfer control lever.
Specified adhesive: 3M Stud Locking No. 4170 or equivalent.
E. Transmission control cable installation (selector lever assembly side). (3)
After installing the transmission control cable, adjust it by the following procedure. 1. Move the
selector lever to the N position. 2. Loosen the adjusting nut, gently pull the end of the transmission
control cable in the direction of the arrow and then tighten the adjusting
nut to the specified torque.
F. Shift lock cable installation (selector lever assembly side). (2)
1. Move the selector lever to the P position. 2. Adjust the shift lock cable so that the end of the
cable (red mark) is at the position shown in the illustration, and then tighten the nut to the
specified torque to clamp the shift lock cable.
3. After installing the shift lock cable, check the shift lock mechanism.
G. Key interlock cable installation (selector lever assembly side). (1)
1. Move the selector lever to the P position. 2. Install the spring and washer that are inserted onto
the key interlock cable as shown in the illustration. 3. Gently push the lock cam until the pin stops in
the direction of the arrow mark as shown in the illustration, and then tighten the nut to the
specified torque to clamp the key interlock cable.
4. After installing the key interlock cable, check the key interlock mechanism.
1. Install front console assembly.

Page 547

Page 6771
Temperature Gauge: Mechanical Specifications
Sensor .................................................................................................................................................
........................................ 10 - 12 Nm (7 - 9 ft. lbs.)
Page 5999
CONTROL UNIT VIEW
Motor Antenna Control Unit D
Page 1871
c. If damp coolant residue or drips are seen, the water pump is defective and it must be replaced.
Refer to Group 14 - Cooling in the service manual for instructions.
WARRANTY INFORMATION This TSB provides information only.
Page 3354


Specifications
Rated load ...........................................................................................................................................
........................................................... High beam : 12 ........................................................................
............................................................................................................................................. Low
beam : 10.8 ..........................................................................................................................................
..............................................................................................................................................................
........ 0.2 V or less
Page 4565


Page 2195
Wire Color Codes
the marking color.


Page 2764
OPERATION
ground.
Page 6648

Locations
Brake Fluid Solenoid Valve Relay: Locations

Page 6641

Page 3734
Page 1162

Page 570

Page 4193
A. Drive pinion front bearing outer race installation. (4)
Use the special tools to press-fit the drive pinion front bearing outer race into the gear carrier.
CAUTION: The bearing outer race must be fitted using a press to avoid tilt and distortion.
B. Drive pinion rear bearing outer race installation. (5)
Use the special tools to press-fit the drive pinion rear bearing outer race into the gear carrier.
CAUTION: The bearing outer race must be fitted using a press to avoid tilt and distortion.
C. Drive pinion height adjustment. (-)
Adjust the drive pinion height by the following procedure:
1. Install the special tools and the drive pinion front and rear bearing inner races into the gear
carrier in the order shown in the illustration. 2. Tighten the handle of the special tool until the
standard value for the drive pinion rotation torque is obtained.
3. Measure the drive pinion rotation torque (without oil seal).
Standard value:
New (with anti-rust agent): 0.6 - 0.9 Nm (5.2 - 7.8 inch lbs.) New/reused (gear oil applied): 0.4 - 0.5
Nm (3.5 - 4.3 inch lbs.)
NOTE: -
Gradually tighten the handle of the special tool while checking the drive pinion rotation torque.
- The one rotation cannot be made when the special tool is in contact with the gear carrier. So
move it a few times and, after seating the
Specifications

........................................... 35 Nm (26 ft. lbs.)
Page 4663


Page 1727
Water Pump: Testing and Inspection
- Check for water leakage. If water leaks from hole "A" seal, unit is faulty. Replace as an assembly.
- Check the seal unit for leaks, and replace the water pump assembly if necessary.
- Check each part for cracks, damage or wear, and replace the water pump assembly if necessary.
- Check the bearing for damage, abnormal noise and sluggish rotation, and replace the water pump
assembly if necessary.
Page 1561
Engine Control Module: Component Tests and General Diagnostics
If there is incorrect or incomplete contact of the engine control module's ground line, the engine
control module will not function correctly.
HARNESS INSPECTION
Engine control module connector: Disconnected OK: STOP NG: Repair the harnesses. (13 -
Ground, 26 - Ground)
Page 2652
(4) Warm up the engine until the coolant temperature is 80°C (176°F) or higher. (5) Using jumper
wires, connect terminal (1) (red clip of the special tool) and terminal (3) (blue clip) of the heated
oxygen sensor with the positive
battery terminal and negative battery terminal respectively.
CAUTION: When connecting the jumper wires, be careful not to connect them to the wrong
terminals, since this could damage the heated oxygen sensor.
(6) Connect a digital voltmeter to terminal (2) (black clip of the special tool) and terminal (4) (white
clip). (7) While repeatedly racing the engine, measure the heated oxygen sensor's output voltage.
Standard value:
(8) If the measurements are not as specified, the cause is probably a malfunction of the heated
oxygen sensor.
NOTE: For removal and installation of the heated oxygen sensor, refer to Exhaust System.
connector [approx. 12 Ohms at a temperature of 20°C (68°F)].
(3) If there is no continuity, replace heated oxygen sensor.
NOTE: 1. If the scan tool dose not display the standard value although no abnormality is found by
the above mentioned continuity test and harness
check, replace the heated oxygen sensor.
2. For removal and installation of the oxygen sensor, refer to Exhaust System.
Page 3679
on actual vehicles.
Wire Color Codes
Locations

Page 5763
^ Effective throughout the temperature range.
^ Guards against rust, corrosion, and wear.
^ Improved shift performance
^ Reduces varnish and sludge build-up.
PARTS INFORMATION
A new chemical reimbursement policy went in to affect on August 4, 1998. See warranty bulletin
WB-99-003 for complete information.
When you use "NON-MMSA" chemicals, fluids, etc. (GENERIC PARTS) the MMSA Warranty
System will now reimburse your dealership for an amount equal to the price of the corresponding
Genuine Mitsubishi MMSA marketed item (+ a 40% markup). If there is no equivalent MMSA
chemical or fluid, MMSA will reimburse for the actual and reasonable cost of the GENERIC item.
Soon, only Genuine Mitsubishi sourced chemicals, fluids, gases, and materials will be reimbursed
on warranty covered repairs. The effective date of this new policy will be announced later in a
Warranty Bulletin. After a phase-in period, dealer sourced generic shop materials, chemicals, etc.
will not be reimbursed. The generic part names will no longer be accepted on warranty claims. The
phase-in period will allow your dealership to deplete existing supplies of aftermarket products and
begin using Genuine Mitsubishi, MMSA supplied materials, fluids, chemicals, and gases. To
summarize, if MMSA sells an item, then MMSA will reimburse up to current dealer net price for
similar generic parts.
For more details about the MMSA chemical program, contact your District Parts Manager.
Page 472
Grounding Markings

Page 626
on actual vehicles.
Wire Color Codes
Page 3444
Page 2047
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
If, during engine warm-up, the fast-idling speed is not correct, or black smoke is emitted, the
problem is usually a malfunction of the coolant temperature sensor.
INSPECTION
Using Scan Tool
HARNESS INSPECTION
Engine coolant temperature sensor connector: Disconnected OK: GO TO STEP 2 NG: Repair the
harness. (A2 - 92)
STEP 2. Check for an open or short-circuit between the engine coolant temperature sensor and the
Engine coolant temperature sensor connector: Disconnected
(A1 - 83)
- Engine control module connector: Connected Ignition switch: ON

Tire Chain - Usage
Tires: Technical Service Bulletins Tire Chain - Usage
NO.: TSB-96-31-003 REV DATE: December, 1996 MODEL: All 1997 Models
SUBJECT:
1997 TIRE CHAIN USAGE
This bulletin supercedes TSB-96-31-003, issued 12/96, to correct Montero Sport tire sizes and tire
chain usage for Galant LS and ES Premium Package
PURPOSE
This bulletin contains tire chain usage recommendations for 1997 Mitsubishi cars and sport-utility
vehicles.
Refer to the "1997 Tire Chain Usage Table" in this bulletin.
AFFECTED VEHICLES
All 1997 models
TIRE CHAIN PRECAUTIONS
All 1997 models have restricted wheel clearances. Use only tire chains known as cable chains,
which meet SAE class "S", clearance specifications. Link-type chains and other traction devices do
not meet these specifications and are not recommended.
The following vehicles cannot use tire chains:
^ Galant LS and ES with Premium Package
^ Eclipse Base, GS, GS-T and GSX
^ Tire chains cannot be used on any 3000GT with factory equipment wheels and tires. However, on
base 3000GT models, if all four original wheels and tires are replaced with 15X6JJ steel wheels
and 205165R15 tires, chains may be used only on the front wheels.
^ Do not use chains on the compact spare wheel of any vehicle. The wheel may be damaged or
cause the tire to come off the wheel.
Observe the following tire chain guidelines:
^ Use tire chains only when necessary.
^ Be sure the chains are the proper size for the tires.
^ Remove wheel covers before installing the chains.
^ Tighten chains as tightly as possible.
^ Drive under 30 mph.
^ If the chains strike the vehicle body or chassis, stop the vehicle immediately and tighten them.
NOTE TO CALIFORNIA DEALERS: Consult your legal counsel for advice regarding customer
disclosure statement for vehicles that cannot use tire chains.
1997 TIRE CHAIN USAGE TABLE

Locations

Page 603
on actual vehicles.
Wire Color Codes
Page 5396
m. Main shaft total starting torque adjustment (-).
1. Use the special tool to measure the main shaft total starting torque while turning the adjusting
bolt.
CAUTION: Adjust by turning the adjusting bolt so that the starting torque at the center position of
the rack piston is approximately 0.2 Nm (2 inch lbs.) higher than the values at the both ends of the
rack piston.
2. Tighten the adjusting bolt lock nut to the specified torque.
n. Pitman arm installation (31).
Install the pitman arm to the gear box so that the mating marks are aligned.
Page 2973
on actual vehicles.
Wire Color Codes
Page 3727

control module.
Locations
CONTROL UNIT VIEW
A/C Control Unit B

NO.: TSB-95-16-003
MODEL: All Models
VEHICLES AFFECTED
All models
PROCEDURE
CAUTION:

Page 628
Specifications

............................................... 12 Nm (9 ft. lbs.)
Specifications
.................................................................... 1.12 W
Page 1126
NOTE: Refer to the refrigerant recovery and recycling unit instruction manual for operation of the
unit.
DISCHARGING THE SYSTEM
Use the refrigerant recovery unit to discharge refrigerant gas from the system.
unit.
SUPPLYING OF OIL IN THE AIR CONDITIONING SYSTEM
Too little oil will provide inadequate compressor lubrication and cause a compressor failure. Too
much oil will increase discharge air temperature. When a 10PA15 compressor is installed at the
factory, it contains 120 cubic cm (4.1 fl.oz.) of refrigerant oil. While the air conditioning system is in
operation, the oil is carried through the entire system by the refrigerant. Some of this oil will trapped
and retained in various pants of the system. When the following system components are changed,
it is necessary to add oil to the system to replace the oil being removed with the component.
Compressor oil: ND-OIL 8
Quantity:
Evaporator: 40 cubic cm (1.4 fl.oz.) Condenser: 40 cubic cm (1.4 fl.oz.) Suction hose: 10 cubic cm
(0.3 fl.oz.) Receiver: 10 cubic cm (0.3 fl.oz.)
Specifications
Piston Pin: Specifications
DIMENSIONS
Outer Diameter ....................................................................................................................................

............................................. 22.0 mm (0.87 inch)
Page 3935
piston No. 2.
remove.
remove.
remove.
INSPECTION
Page 3464
position sensor.

Page 2001

Page 1116
^ Effective throughout the temperature range.
^ Guards against rust, corrosion, and wear.
^ Improved shift performance
^ Reduces varnish and sludge build-up.
PARTS INFORMATION
A new chemical reimbursement policy went in to affect on August 4, 1998. See warranty bulletin
WB-99-003 for complete information.
When you use "NON-MMSA" chemicals, fluids, etc. (GENERIC PARTS) the MMSA Warranty
System will now reimburse your dealership for an amount equal to the price of the corresponding
Genuine Mitsubishi MMSA marketed item (+ a 40% markup). If there is no equivalent MMSA
chemical or fluid, MMSA will reimburse for the actual and reasonable cost of the GENERIC item.
Soon, only Genuine Mitsubishi sourced chemicals, fluids, gases, and materials will be reimbursed
on warranty covered repairs. The effective date of this new policy will be announced later in a
Warranty Bulletin. After a phase-in period, dealer sourced generic shop materials, chemicals, etc.
will not be reimbursed. The generic part names will no longer be accepted on warranty claims. The
phase-in period will allow your dealership to deplete existing supplies of aftermarket products and
begin using Genuine Mitsubishi, MMSA supplied materials, fluids, chemicals, and gases. To
summarize, if MMSA sells an item, then MMSA will reimburse up to current dealer net price for
similar generic parts.
For more details about the MMSA chemical program, contact your District Parts Manager.
Specifications
Differential Carrier: Specifications
TORQUE SPECIFICATIONS
Ring gear bolts: ...................................................................................................................................

................................ 137 - 167 Nm (101 - 123 ft. lbs) Companion flange: ..........................................
....................................................................................................................................... 216 Nm (159
ft. lbs) Carrier bearing cap bolts
.............................................................................................................................................................
55 - 65 Nm (40 - 47 ft. lbs) Bearing lock plate bolts ............................................................................
................................................................................................. 19 Nm (14 ft. lbs) Air pipe banjo bolt .
..............................................................................................................................................................
...................... 15 Nm (11 ft. lbs) Air pipe retainer bolts .......................................................................
............................................................................................................. 9 Nm (7 ft. lbs) Rear
differential lock detection switch
...................................................................................................................................................... 36
Nm (27 ft. lbs)
Page 6073
Page 5917
Impact Sensor: Service and Repair

CAUTION:
1. Never repair or disassemble a front impact sensor. If faulty, replace it. 2. Handle the front impact
sensors very carefully, taking care not to drop them or otherwise subject them to impact. If a sensor
is seen to be dented,
cracked, deformed or rusted, replace it with a new one
3. Replace sensors with new ones after the air bags have deployed.
- Turn the ignition key to the "LOCK" position.
Removal Steps
1. Negative (-) battery cable connection 2. Front impact sensor (R.H) -
Reserve tank
3. Front impact sensor (L.H) -
work.
Page 3810
1997 & 1998 Montero Service Manuals, Volume 1, Page 23B-6 Add the new forward clutch piston
stroke measuring tool as shown.
Page 3917
Overdrive Assembly: Service and Repair Overdrive Support
DISASSEMBLY
INSPECTION
Page 3394
Page 5608
Tires: Pressure, Vacuum and Temperature Specifications
Tire Inflation Pressure
Front ....................................................................................................................................................
............................................... 180 kPa (26 psi) Rear ..........................................................................
.......................................................................................................................... 220 kPa (32 psi)
Page 5438
1998, 1999, & 2000 Montero Service Manuals, Volume 2, page 37A-19
Page 97
RELAY VIEW
Taillight Relay B
Page 2110

Page 4687


Page 6274
Back Door Window Defogger And Mirror Heater (Part 2 Of 2)
Locations
Power Door Lock Control Module: Locations

Page 4647

Page 4125
5. Install the spring, cutback valve and plug as illustrated. 6. While pushing the plug with a finger,
install the key.
7. Install the spring, secondary regulator valve and plug as illustrated. 8. While pushing the plug
with a finger, install the key.
9. Install the lockup relay valve plunger and spring to the lockup relay valve sleeve as illustrated.
10. Install the lockup relay valve to the lockup relay valve sleeve. 11. Install the lockup relay valve
sleeve, lockup relay valve, spring, and lockup relay valve plunger together as illustrated. 12. Install
the seat.
13. Install the spring, second coast modulator valve and plug as illustrated. 14. While pushing the
plug with a finger, install the seat.
15. Install the spring, 3-4 shift valve and plug as illustrated. 16. While pushing the plug with a
finger, install the seat.
Page 3246
NG: Repair the harness. (A1 - 2, A2 - 14, A3 - 1, A5 - 16, A6 - 3, A7 - 15)
INJECTOR CHECK Measuring Resistance Between Terminals
(1) Disconnect the injector intermediate harness.
(2) Measure the resistance between the terminals.
(3) Connect the injector intermediate harness.

Specifications
Engine Oil Drain Plug: Specifications
Plug .....................................................................................................................................................
.................................................. 40 Nm (30 ft. lbs.)
Specifications
Transmission Shift Position Indicator Lamp: Specifications
Automatic transmission indication light ................................................................................................
..................................................................... 1.12 W
Page 2837

Page 3259
1999 Montero Service Manual, Volume 1, Page 13A-91 Correct the description of the fuel pump
relay as shown:
Page 6194
Page 3772
INSPECTION
the ground.
Page 2888
STEP 2. Check for an open circuit or a short-circuit to ground between the heated oxygen sensor
and the engine control module. -
(A4 - 76, B4 - 79)
(A3 - 34, B3 - 42)
- Engine control module connector: Disconnected OK: STOP NG: Repair the harness. (A2 - 92, B2
- 92)

Page 3548
23, D3 - 10)
Page 1071
Fluid - A/T: Fluid Type Specifications
Transmission fluid
Type
......................................................................................................................................................
DIAMOND ATF SP or DEXRON II or Equivalent
Locations

SENSOR VIEW
Page 822
increased.

Page 141
Page 5263
on actual vehicles.
Wire Color Codes
Vehicles With Limited Slip Differential
Differential Case: Service and Repair Vehicles With Limited Slip Differential
Disassembly
NOTE: Gear oil: MITSUBISHI Genuine Gear Oil or equivalent.
CAUTION: Apply the specified gear oil to each component; especially be careful to coat contact
surfaces and sliding surfaces.

Specifications
Differential: Specifications
End Play:
Center Differential
...................................................................................................................................... 0.025-0.150
mm (0.00098-0.00591 inch) Differential Lock Hub
.......................................................................................................................................................
0-0.08 mm (0-0.0031 inch)
Center Differential Case ......................................................................................................................

........................................... 65 Nm (47 ft. lbs.)
Page 3697


Page 2552
Wire Color Codes
the marking color.

Page 3842
drum.
illustration.
Page 519
Removal
Installation
Page 912
Page 5778
Refrigerant Oil: Fluid Type Specifications OIL TYPE
OIL TYPE
ND Oil 8, Or Equivalent
Page 1597

Page 867
Grounding Markings

Specifications

............................................ 15 Nm (11 ft. lbs.)
Specifications
Sensor Bolt
Torque 7 ft.lb
Page 3806
1996 Montero Service Manual, Volume 1, Page 23C-14 Add the new forward clutch piston stroke
measuring tool as shown.
SRS Cautions and Warnings - Revision
Air Bag: Technical Service Bulletins SRS Cautions and Warnings - Revision
NO.: TSB-97-52B-003 Date: September, 1997 Model: See below
Subject: SRS CAUTIONS AND WARNINGS - SERVICE MANUAL REVISION
[TSB Revision TSB-97-52B-003]
PURPOSE Cautions and warnings for the supplemental restraint system (SRS) have been
changed as shown in the corrected service manual pages in this bulletin.
^ For 1997-on models, SRS glovebox labels must not be removed except by the new vehicle
owner.
NOTE:
SRS glovebox labels can be replaced by ordering part number MR381707.
^ Replace all damaged or dirty (illegible) SRS caution and warning labels.
^ Replace the air bag modules after air bag deployment. Also check the clock spring and replace if
necessary.
AFFECTED VEHICLES 1992-97 3000GT
1996-97 Eclipse Spyder 1992-97 Mirage
1992-96 Diamante 1992-96 Expo/Expo LRV 1992-97 Montero
1995-97 Eclipse 1995-97 Galant 1997 Montero Sport
AFFECTED SERVICE MANUALS 1992-96 3000GT, Volume 1, page 52B-74 1997 3000GT,
Volume 1, pages 52B-4, 52B-5, 52B-30 1992-96 Diamante, Volume 1, page 52B-82 1995 Eclipse,
Volume 1, page 52B-48 1996 Eclipse, Volume 1, page 52B-35 1997 Eclipse/Eclipse Spyder,
Volume 1, pages 52B-4, 52B-5, 52B-34 1992-96 Expo/Expo LRV, Volume 1, page 52B-60 1995
Galant, Volume 1, page 52B-52 1996 Galant, Volume 1, page 52B-52 1997 Galant, Volume 1,
page 52B-4, 52B-5, 52B-31 1992-96 Mirage, Volume 1, page 52B-64 1997 Mirage, Volume 1, page
52B-4, 52B-5, 52B-27 1997 Mirage Technical Information Manual, page 6-13, 6-14 1992-95
Montero, Volume 1, page 52B-45 1996 Montero, Volume 1, page 52B-48 1997 Montero, Volume 1,
page 52B-4, 52B-5, 52B-36 1997 Montero Sport, Volume 2, page 52B-4, 52B-5, 52B-53 1997
Montero Sport Technical Information Manual, page 6-12,6-13
Add the caution information below to the following service manual pages:
1997 3000GT, Volume 1, page 52B-30 1992-96 Diamante. Volume 1, page 52B-82 1995 Eclipse,
Volume 1, page 52B-48 1996 Eclipse, Volume 1, page 52B-35 1997 Eclipse/Eclipse Spyder,
Volume 1, page 52B-34 1992-96 Expo/Expo LRV, Volume 1, page 52B-60 1995 Galant, Volume 1,
page 52B-52 1996 Galant, Volume 1, page 52B-52 1997 Galant, Volume 1, page 52B-31 1993-96
Mirage, Volume 1, page 52B-64
AIR BAG MODULE AND CLOCK SPRING

Diagrams
Page 2780
Grounding Markings

Page 2027
Page 2971

Page 957
Side Slip
Measure the side slip with a side slip tester.
Standard value: (0 ± 3 mm (0 ± .12 inch)) -3 mm to +3 mm (-.12 to +.12 inch)

Page 1591

Page 2590

Page 7029


Page 1837
INSPECTION
Using Scan Tool
HARNESS INSPECTION
harness. (A2 - 92)
(A1 - 83)

Page 6722

Page 3543
Component View
Ignition Power Transistor C
Specifications

............................................ 15 Nm (11 ft. lbs.)
Page 1359
Crankshaft: Testing and Inspection Pin/Journal Oil Clearance (Plastigage Method)
The crankshaft oil clearance can be measured easily by using Plastigage, as follows:
1. Remove oil and grease and any other foreign matters from the crankshaft journal and bearing
inner surface. 2. Install the crankshaft. 3. Cut Plastigage to the same length as the width of the
bearing and place it on the journal in parallel with its axis. 4. Gently place the crankshaft bearing
cap over it and tighten the bolts to the specified torque. 5. Remove the bolts and gently remove the
crankshaft bearing cap.
6. Measure the width of the crushed Plastigage at its widest section by using a scale printed on the
Plastigage package.
7. Measure the outside diameter of the journals and the inside diameter of the crankshaft bearings.
If the difference between them (oil clearance)
exceeds the limit, replace the crankshaft bearing and, if necessary, crankshaft. Standard value:
0.02 - 0.04 mm (0.0008 - 0.0016 inch) Limit: 0.1 mm (0.004 inch)
NOTE: Do not attempt an undersize machining of the crankshaft with special surface treatment.
This crankshaft can be identified by its dull gray appearance.
Page 4347
Drive/Propeller Shaft: Overhaul
DISASSEMBLY
Make mating marks on the yokes of the universal joint that is to be disassembled.
B. Journal bearing removal. (3)

Page 3930
Page 7121

Page 7120
Grounding Markings

Page 531


Page 1516
2. Degrease the sealant coated surface and the engine mating surface. 3. Apply Mitsubishi
Genuine Part No. MD970389, or equivalent sealant, around the gasket surface of the oil pan as
shown.
diameter.
4. Install the oil pan to the cylinder block within 30 minutes after applying the sealant. 5. Tighten the
oil pan mounting bolts in the order shown to 6 Nm (4 ft. lbs.).
CAUTION: The bolt holes for bolts 15 and 16 in the illustration are cut away on the transmission
side, so be careful not to insert these bolts at an angle.
Page 3601
Crankshaft Position Sensor: Oscilloscope Patterns and Waveforms
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Page 1902
12. When the message "It transfers data to the memory card. Are you ready?" displays, press the
check mark button.
13. A progress monitor displays during data transfer to the memory card.
14. When the message "Transfer is complete" appears, press the check mark button.
To remove the memory card:
15. Double-click the removal icon in the lower right corner of the screen.
16. Select "PCMCIA IDE/ATAPI Controller" . Then press the Stop button.
17. Verify that the correct item is selected, then press the OK button.
When the message "The device can now be safely removed from the system" displays, remove the
memory card (press the button next to the PC card slot).
II. Reprogramming A Vehicle ECU With the Vci
After data is in the memory card, it can be downloaded to the VCI, then to the vehicles PCM (ECU).
NOTE: Whenever the ECU is reprogrammed, a reprogramming label (p/n MSSF-024G-00) must be
completed and affixed to the vehicle. Refer to the applicable reprogramming TSB for specific
information that must be entered on the label.
VCI COMPONENTS
Page 3327
RELAY VIEW

Page 4401

Locations

Page 2852

Audio System - Speaker Static/Buzzing/Inoperative
Radio/Stereo: Customer Interest Audio System - Speaker Static/Buzzing/Inoperative
No: TSB-04-54-002REV DATE: June, 2004 MODEL: All
SUBJECT: AUDIO SPEAKER TROUBLESHOOTING AND REPLACEMENT GUIDELINES
This TSB supercedes TSB-04-54-002, issued February 2004, to include speaker locations on the
Speaker Complaint Checklist and a new warranty statement requiring Checklist submittal.
Revisions are indicated by -->.
PURPOSE
This bulletin contains troubleshooting steps for diagnosing various customer complaints relating to
the audio system speakers in Mitsubishi vehicles.
Symptom/Condition
You may receive customer complaints about abnormal noise from the audio system speakers.
These can be described as any of the following:
^ Static
^ Popping
^ Crackle
^ Buzzing
^ Rattle
^ Distorted sound
^ Poor sound quality
^ No sound (speaker inoperative)
Proper diagnosis of speaker or speaker related conditions is important for customer satisfaction
and correct warranty reporting. Some of these reported abnormal sounds, which are often
attributed to the speakers, may have other origins. Speakers are often replaced without the actual
problem being solved. In some cases, supposedly faulty speakers returned for warranty have been
checked by the speaker manufacturer with no problem found. Make sure the suspected speaker is
carefully evaluated before replacement. Use the troubleshooting procedures represented in the
three flowcharts in this bulletin to help diagnosis speaker related conditions.
CHECKLIST REQUIRED
If warranty speaker replacement is required, the SPEAKER COMPLAINT CHECKLIST at the end
of this bulletin MUST be completed and attached to the replaced speaker and held until the
subsequent request for return is issued. Make copies of the Checklist and use it each time warranty
speaker replacement is required.
AFFECTED VEHICLES
All Mitsubishi models and model years
PROCEDURE
Page 2215

Page 6890

Wheel Speed Sensor: Electrical Specifications
Insulation Resistance 100,000 ohms
Internal Resistance: Front 1170-1350 ohms
Rear 1300-1500 ohms

Page 2536
Step 2: Erases data in the ECU.
Step 3: Writes new data in the ECU.
Step 4: Verifies the new data is transferred.
Step 5: Erases diagnosis and back-up memory.
MANUAL REPROGRAMMING
1. In the main menu, select "Load RPG file". Then press ENTER.
2. Select the reprogramming database by using the down arrow. Then press ENTER.
Page 254
Control Module: Electrical Diagrams

Active Trac 4WD System (Part 1 Of 2)
Page 1131
Refrigerant Oil: Fluid Type Specifications OIL TYPE
OIL TYPE
ND Oil 8, Or Equivalent
Page 7028

Page 4083
Page 3825
Locations
Brake Fluid Pump Relay: Locations

Page 3904
1. Aligning the convex of the thrust washer No. 1 with the hole of the rear planetary gear, install the
washer to the gear.
2. Turn the rear planetary gear over. Aligning the convex of the thrust washer No. 2 with the hole of
the rear planetary gear, install the washer
to the gear.
G. One-way clutch No. 2 installation. (8)
1. Install the one-way clutch No. 2 to the rear planetary gear in the illustrated direction.
H. One-way clutch inner race installation. (6)
1. After the one-way clutch inner race is installed, check the operation of the one-way clutch No. 2
as follows:
2. While holding the rear planetary gear, turn the one-way clutch clockwise to see that the clutch is
locked and turn it counterclockwise to see
that the clutch turns.

4WD Indicator Control Unit
Control Module: Locations 4WD Indicator Control Unit
Page 7127
Vanity Lamp: Testing and Inspection
The vanity mirror does not illuminate.
- Check the vanity mirror switch.
- Check the vanity mirror light bulb.

Page 503

SENSOR VIEW

Specifications

...................................................... 2,000 ± 100 Ohms
Page 3859
DISASSEMBLY

Locations

Page 3839
Clutch: Service and Repair Second Brake
DISASSEMBLY
B. Second brake piston removal. (7)
1. With the second brake piston held, blow air into the second brake drum through the oil hole to
remove the second brake piston.
remove.
INSPECTION
Page 4175
3. Use the special tools to measure the drive pinion rotation torque (without the oil seal).
Standard value:
New (with anti-rust agent): 0.3 - 0.5 Nm (2.6 - 4.3 inch lbs.) New/reused (gear oil applied): 0.15 -
0.25 Nm (1.3 - 2.2 inch lbs.)
NOTE: -
Gradually tighten the handle of the special tool while checking the drive pinion preload.
- Because one rotation cannot be made when the special tool is in contact with the gear carrier,
move it a few times and, after seating the bearing, measure the rotation torque.
4. Position the special tool in the side bearing seat of the gear carrier, and then select a drive
pinion front shim of a thickness which
corresponds to the gap between the special tools.
NOTE: -
Be sure to clean the side bearing seat thoroughly. When positioning the special tool, check that the
cut-out sections of the special tool are in the position shown in the illustration, and check that the
special tool is in close contact with the side bearing seat.
- When selecting the drive pinion front shims, keep the number of shims to a minimum.
5. Fit the selected drive pinion front shim(s) to the drive pinion, and then use the special tool to
press-fit the drive pinion front bearing inner
race.
D. Drive pinion rotation torque adjustment. (-)
Adjust the drive pinion rotation torque by the following procedure:
Without oil seal:
1. Insert the drive pinion into the gear carrier, and then install the drive pinion spacer, drive pinion
rear shim, drive pinion rear bearing
inner race and companion flange in that order from the front of the carrier.
NOTE: Do not install the oil seal.

Page 2681
For Outlander and 2002-on Montero models, use 12-pin to 13-pin adapter harness MB991855 to
connect the main harness to the data link connector.
4. Turn the ignition switch to the ON position.
MAIN MENU
Turn the ignition key to ON. When the VCI unit is turned on, the main menu displays:
IMPORTANT
^ When connecting and disconnecting, do not pull on the harness wires. Pull only on the
connectors.
^ During reprogramming, the ignition switch must remain ON.
^ Do not disturb the MUT-III main harness during reprogramming. After reprogramming, start the
engine to verify operation.
Automatic reprogramming is recommended for most typical reprogramming situations. If automatic

reprogramming is not successful, try manual reprogramming.
AUTOMATIC REPROGRAMMING
1. In the VCI main menu. select "Automatic RPG". Then press ENTER.
The available data will display.
2. Press ENTER. If the PCM requires reprogramming, the MUT-Ill will automatically identify the
appropriate database. Press ENTER again to transfer the reprogramming data to the VCI.
a. If the PCM does NOT require reprogramming, this message displays. Press ENTER to return to
the main menu.
b. If there is no data for reprogramming this PCM, this message displays and no data is
transferred. Press ENTER to return to the main menu.
Page 6045
Page 5268
the standard value.

the system.
Page 2162
Wire Color Codes
the marking color.

Page 894
Component View
Page 3482
Grounding Markings

Page 3834
piston No. 2.
remove.
remove.
remove.
INSPECTION
Page 3145
Positive Crankcase Ventilation Valve: Testing and Inspection
1. Hold the PCV valve vacuum side down. Using light pressure, depress the PCV valve spring with
the thin stick 5 - 10 mm (0.20 - 0.39 in.). Release
pressure on the stick to see if the PCV valve spring will lift the stick to its original position.
2. If the stick returns quickly to its original position, the PCV valve is OK. If the stick does not return
quickly, clean or replace the PCV valve.
Page 2937
OPERATION
control module.
rotation.
Page 2424
Grounding Markings


relay.
AFFECTED VEHICLES
1997-99 Montero

Page 4574
INSPECTION
transfer case.
transfer case.
transfer case.

Page 4348
1. Use the special tool to press in the journal bearing on one side, and take out the journal bearing
on the opposite side.
2. Insert the special tool in the other side and press the journal to remove the first journal bearing
that was pushed.
CAUTION: Do not tap the journal bearings to remove them, as this will upset the balance of the
propeller shaft.
ASSEMBLY
A. Journal/journal bearing installation. (3 & 4)
1. Fit the journal onto the yoke.
2. Use the special tool to press the journal bearing into the yoke until the snap ring groove is fully
visible.
Page 2592

Page 1136
Page 4935
Vacuum Brake Booster: Specifications
DIMENSIONS
Diameter Of Power Cylinder

................................................................................................................................................ 205 or
230 mm (8 or 9 inch)
Mounting Nuts .....................................................................................................................................

................................................ 14 Nm (10 ft. lbs.) Vacuum Hose/Check Valve
......................................................................................................................................................
15-18 Nm (11-13 ft. lbs.)
Page 2956


Page 3265

Page 3465
follows.
that position.
Page 6454
Component View
Buzzer Assembly F
Page 533
Wire Color Codes
the marking color.

Page 5572
a. Shock absorber/actuator (vehicles with remote controlled variable shock absorbers) installation
(3 & 4).
Tighten the nut so that the values shown in the figure (A and B) are at the standard values.
Standard value
(A): 1 - 2 mm (.04 - .08 inch) (B): 1.5 - 2.5 mm (.06 - .10 inch)
Page 5494
Rear Knuckle: Service and Repair Overhaul
DISASSEMBLY
A. Needle bearing removal. (3)
1. Remove the oil seal and take out the spacer. 2. Drive out the needle bearing by tapping the
needles uniformly.
CAUTION: Once removed, the needle bearing must not be reused.
ASSEMBLY
A. Needle bearing installation. (3)
1. Apply multi-purpose grease to the roller surface of the new needle bearing.
Page 2048
sensor.

Page 1751
Fan Clutch: Service and Repair
Refer to the illustration for the service procedure.

Page 5553
Shock Absorber Mounting Bolts (Lower Side)
................................................................................................................... 215-245 Nm (159-181 ft.
lbs.)
NOTE: (*) Vehicles with optional remote-controlled variable shock absorbers.

Page 402
Dimmer Switch: Testing and Inspection
Rheostat
1. Remove the knee protector. 2. Remove the rheostat from the instrument panel.
Rheostat
3. Connect the battery and the test light (40 W) as shown in the illustration. 4. Operate the rheostat,
and it the brightness changes smoothly without switching off, then the rheostat function is normal.
Page 2154
Component View
Locations

Page 3977
Page 6970


Page 4666

Page 817
OPERATION

relay.
AFFECTED VEHICLES
1997-99 Montero

Page 3064
Catalytic Converter: Service and Repair Federal

Page 4396
CONTROL UNIT VIEW
Page 2540
Vehicle battery voltage is low
If the battery voltage is below 9.8 V, this error will display for five seconds.
Recharge or replace the battery. Press ENTER to continue.
Download Error
This message displays if:
- the MUT-III harness is disconnected during reprogramming
- the ignition switch is turned off during reprogramming
- a communication problem occurs during reprogramming
- battery voltage is low
No response from vehicle ECU
- the vehicle ECU does not require reprogramming
- the ignition switch is off
Checking ECU download error

Front Axle
Fluid - Differential: Testing and Inspection Front Axle
Remove the filler plug and check the gear oil level. Check that the gear oil level is not 8 mm (0.31
inch) below the bottom of the filler plug hole.
Specified gear oil: Hypoid gear oil API classification GL-5 or higher, SAE viscosity No. 9O, 80W
[1.15 dm3 (1.22 qts.)]
Specifications
Wheels: Specifications
Runout Limit:
Lateral ..................................................................................................................................................
........................... 1.0 mm (.04 inch) or less Radial ..............................................................................
............................................................................................... 1.0 mm (.04 inch) or less
Catalytic Converter: Testing and Inspection
CAUTION: 1. Stop the engine immediately if engine misfiring occurs, otherwise an abnormally hot
exhaust system will damage the catalytic converter or
other underbody parts.
2. Correct and repair the ignition or fuel system if there are malfunctions, otherwise engine misfiring
may occur which will damage the catalytic
converter.
3. Observe manufacturer's specifications when doing service work.

Actuator: Testing and Inspection
1. Remove the rear differential lock air pump and remove the air hose from the air pump. 2.
Connect a pressure gage and air regulator, for adjusting the compressed air pressure to the air
hose. 3. Adjust the compressed air pressure with the air regulator until the pressure gage shows a
pressure of approximately 35 kPa (5 psi.).
4. Shut off the air valve. 5. If after approximately 10 minutes have passed, the pressure has
dropped, it can be concluded that there is no leaking of air from the air hose, etc.
Page 6289
Paint: Application and ID
BODY COLOR CHARTS
Check the vehicle's body color code, and then use this body color chart to determine the refinishing
paint supplier from which the color can be purchased.
COLORED PEARL COATING (AC10925)
The surface of the mica powder is colored by a coating with titanium dioxide and then by a coating
of colored inorganic compound The hue is determined by the base color of the mica powder
blending with the color of the colored inorganic compound. For kutani red (R25), the materials are
white mica powder coated with a string red-colored iron oxide.
Locations

SENSOR VIEW
Page 4081
Page 4174
Use the special tool to insert the oil seal, and then apply a thin coat of multi-purpose grease to the
lip of the oil seal.
B. Drive pinion front bearing outer race/ drive pinion rear bearing outer race installation. (5)
Use the special tools to press-fit the drive pinion front bearing outer races into the gear carrier.
NOTE: Carry out press-fitting carefully so as not to tilt the outer race.
C. Pinion height adjustment. (-)
Adjust the drive pinion height by the following procedure:
1. Install the special tools and the drive pinion front and rear bearing inner races into the gear
carrier in the order shown in the illustration. 2. Tighten the handle of the special tool until the
standard value for the drive pinion rotation torque is obtained.
Page 1518
Oil Pan: Diagrams

Page 2323

Page 3690
CONTROL UNIT VIEW

Page 183
Inspection
HARNESS INSPECTION
NOTE -
Page 3857
Direct Clutch Disc
the limit.
Direct Clutch Piston
Direct Clutch Piston Stroke
1. Install the direct clutch to the overdrive support assembly. 2. Using a dial gauge, measure the
piston stroke by applying compressed air (400 - 800 kPa, 57 - 113 psi) into the oil hole of the
overdrive
support as shown and then releasing the air.
Standard value: 1.37 - 1.67 mm (0.0539 - 0.0657 inch)
Page 901
on actual vehicles.
Wire Color Codes
Page 2882
Oxygen Sensor: Description and Operation California
OPERATION
Page 2252
OPERATION
Page 5628
Use snap ring pliers to remove the snap ring from the drive shaft.
CAUTION: The proper tool for removing and installing the snap ring is a pair of snap ring pliers.
Using a screwdriver or other tool can deform or spread the snap ring beyond its yield point. Be sure
to use only snap ring pliers for removing and installing this snap ring.
B. Front brake assembly removal. (5)
1. Remove the front brake assembly with the brake hose connected. 2. Use wire to suspend the
front brake assembly from the upper arm so that the front brake assembly won't fall.
CAUTION: Do not twist the brake hose.
C. Lock nut/front hub assembly removal. (8 & 9)
1. After removing the lock washer, remove the lock nut with the special tool. 2. Remove the front
hub assembly from the knuckle together with the inner and outer bearings.
INSPECTION
1. Check the wheel bearing for seizure, discoloration and rough raceway surface. 2. Check the
front hub for cracks. 3. Check the oil seals for cracks or damage.
INSTALLATION
A. Wheel bearing preload adjustment. (-)
1. Use the special tool to tighten the lock nut by the following procedure:
a. Tighten to 162 Nm (119 ft. lbs.). b. Loosen to 0 Nm (0 ft. lbs.). c. Re-tighten to 25 Nm (18 ft. lbs.)
and then loosen 30-40°.
Page 2176
Wire Color Codes
the marking color.

Page 4121
4. Remove the downshift plug, spring and throttle valve.
5. Remove the spring and E-rings from the rear of the valve body.
CAUTION: Because the throttle pressure changes depending on the number of E-rings, remember
how many E-rings have been used (sometimes zero).
7. Remove the plug, 3-4 shift valve and spring.
Page 688
position sensor.

Page 2743

Locations

Locations

Page 180
Component View
Specifications
Shift Solenoid: Specifications
Lock Up Solenoid ................................................................................................................................

.................................... 10 Nm (86.4 inch lbs.) Shift Solenoid No. 1 ....................................................
............................................................................................................. 10 Nm (86.4 inch lbs.) Shift
Solenoid No. 2 .....................................................................................................................................
............................ 10 Nm (86.4 inch lbs.)
Page 2081

Page 4421


Page 2245

Page 2915
on actual vehicles.
Wire Color Codes
Page 3385
Throttle Position Sensor: Locations

SENSOR VIEW
Throttle Position Sensor B

Page 5256
Component View
Specifications
Brake Pad: Specifications
Lining Thickness: Front 0.390 in
Rear 0.354 in
Minimum Thickness: Front 0.079 in
Rear 0.079 in
Page 3120
Federal Vehicles Only

Page 863
Component View
Page 5412
Steering Wheel: Testing and Inspection Stationary Steering Effort Check
1. Place the vehicle on a level surface and set the steering wheel to the straight-ahead position. 2.
Start the engine and set it to 1,000 rpm.
CAUTION: After checking the engine rpm, there must be a return to the standard idling rpm.
3. Measure the tangential force with a spring balance by turning the steering wheel clockwise and
counter clockwise one and a half turns.
Standard value: 37 N (8.21 lbs.) or less
4. If the stationary steering effort exceeds the standard value, check for belt slackness, damage,
insufficient oil, air mixed into oil, collapsed or
twisted hoses, etc., and repair if found.

Page 4239
OPERATION CHECK
pressure equalizes.

Locations
Lock-Up Solenoid
INSPECTION
and the ground.
Page 5725
PARTS INFORMATION
Use the genuine Mitsubishi Parts listed.
Page 2632
SENSOR VIEW
Heated Oxygen Sensor(front) S
Heated Oxygen Sensor(rear) T

Specifications
Front Hub:

.......................................................................................................................................... 0.05 mm
................................................................................................................................................. 0.3 -
1.3 Nm (2.6 - 11.3 inch lbs.)

.......................................................................................................................................................... 5
- 8 N (1.1 - 4.0 lbs.)
Service and Repair
Keyless Entry Transmitter Battery: Service and Repair
1. Remove the set screw to remove the battery from the transmitter. 2. Install a battery with its (+)
side face-down.
Note: Battery required for replacement: Coin type battery CR2032
3. Insert the claw first, and with care not to displace the 0-ring, assemble the transmitter.
Note: Do not let water or dust stick to the inside of the transmitter when its open. Also, do not touch
the precision electronic device. If the 0-ring is displaced during the assembly of the transmitter,
water or dust penetrates it, causing trouble.
Page 6284
Elcometer 246 F (Electric/Digital)-Suggested retail price $600.00
ProGauge (Mechanical)-Suggested retail price $30.00
Paint Damage Causes
It helps to inspect the paint surfaces outdoors as well as indoors under fluorescent lights. Some of
the affected areas may show up better with the help of inside lighting. Sometimes you can feel the
damage; other times it takes more than a touch. The key here is to carefully verify the extent of
damage to find a way to repair the affected areas without having to repaint the panel or sometimes
the entire vehicle.
Acid Rain
Acid rain forms when pollution is combined with rain and/or moisture in the atmosphere. When
Sulfur Dioxide and Nitrogen Oxides mix with water molecules, they form a weak Sulfuric Acid and
Nitric Acid, otherwise known as Acid rain.
As the rain evaporates the acid concentration increases, creating pits in the surface. This damage
is further accelerated by sunlight.
Rail Dust
Rail dust is iron particles that fall onto the paint which occurs during transportation. These airborne
iron particles become embedded into the paint finish on contact. This causes a rough finish and
stains the surface, which is created by the iron dissolving when moisture or water are present.
Scratches
Scratches are the result of contact of a hard object with the painted surface. Some scratches found
on new vehicles are caused by tiedown chains used during transportation. Swirl Marks
Swirl marks are fine scratches remaining from incomplete or improper buffing operations.
Paint Damage Classifications

Again, paint damage should be inspected both outdoors with natural light and indoors under
fluorescent lights. It is important to inspect each vehicle at the time of delivery for paint damage.
The earlier the damage is found, the easier it is to repair.
All the previously mentioned types of damage can be classified as Minor Damage, Major Damage,
and Rail Dust.
Minor Damage is small pits in the paint surface caused by pollution, such as acid rain, rail dust,
scratches, swirl marks and organic pollution. The average depth is about 0.2 mils, (.0002"). To
correct minor damage, use a buffing procedure.
Major Damage is more severe pitting. The depth of this damage can range from approximately 0.2
mils to 0.4 mils, (.0002"-.0004"). To correct major damage, wet sanding and buffing will be
necessary. Any damage more than 0.5 mils deep will require repainting of the affected area.
Rail Dust can be either minor or major damage depending on the severity. The difference in
repairing rail dust is the method of repair. For rail dust first remove the iron particles by using an
Industrial Fallout Remover. After the rail dust particles have been removed, small pits will be left in
the paint. Repair these pits by using the appropriate procedure (i.e., minor or major damage
repair).
Required Materials
Page 437
NOTE:
Page 1368
This bulletin provides specific vehicle application and general information on engine block heaters.
The chart shown identifies the appropriate block heater kit, installation location, and positioning
direction for most vehicles distributed by Mitsubishi Motor Sales of America, Inc.
GENERAL DESCRIPTION
Engine block heaters are used to maintain coolant fluidity inside the engine's coolant passages.
Coolant fluidity is a factor when vehicles are parked in extremely cold areas (0°F or less) for
extended periods of time. A block heater consists of a heating element, O-ring, electrical connector,
and a power cord.
The block heater is the same shape and diameter as the engine's core plugs and permanently
replaces a designated core plug. Refer to the chart included for block heater part numbers,
application information, and core plug location and position.
Page 6182
1. With the third-seat folded up in the stowed position, look at the shape of the striker holes in the
cargo area carpet (mat). If "T"-shaped, proceed with modifications. Also, check the third-seat
striker/latch assemblies for proper operation. If the striker holes are rectangular (dimensions 63 mm
x 97 mm), the mat has already been modified. In this case, go to step 5.
2. Remove the cargo area mat. On the back side of the mat, mark the new rectangular hole at each
of the original "T"-shaped striker holes. Use the included template as a guide.
NOTE:
Make sure to pay close attention to the positioning of the template. The new rectangular-shaped
hole should start at the bottom of the original "T"-shaped hole, and extend exactly 21 mm above
the top of the "T". The 21 mm dimension is critical for proper striker operation.
WARNING:
3. Be careful to avoid injury when using the knife to cut the mat.
Using a sharp carpet knife and a straight edge, cut out the new rectangular shape at each
"T"-shaped striker hole.
NOTE:
Page 10
Input Speed Sensor
INSPECTION
Page 3840
ASSEMBLY

CAUTION: Be sure the end gap of the snap ring is not aligned with the stopper of the spring seat.
Page 1813
Radiator Cap: Testing and Inspection
1. Use a cap adapter to attach the cap to the tester. 2. Increase the pressure until the indicator of
the gauge stops moving.
- Standard value: 75 - 105 kPa (11 - 15 psi)
- Limit: 65 kPa (9.2 psi)
3. Replace the radiator cap if the reading does not remain at or above the limit.
NOTE: Be sure that the cap is clean before testing, since rust or other foreign material on the cap
seal will cause an improper indication.
Locations
Electronic Noise Suppressor: Locations
Other Devices Location Views A - B

Page 1370
6. Fill the cooling system with a clean, properly mixed ratio (normally 50/50) of coolant and water.
Do not use cooling system additives designed to prevent leaks.
!CAUTION
If the heating element is operated while not immersed in coolant, it will quickly burn out and the
block heater will be inoperable.
PARTS INFORMATION
Refer to the block heater application chart.

Page 6706
Seat Belt Reminder Lamp: Description and Operation
- This indicator illuminates for four to eight seconds when the ignition switch is at the ON position,
even if the driver has fastened his seat belt.
Page 230
Grounding Markings

Page 6957
Horn Relay: Testing and Inspection
Horn Relay
Horn Relay - Check
1. Remove the horn relay from the engine compartment. 2. Apply battery positive voltage to
terminal (2), and check for continuity between the terminals when terminal (4) is grounded.
Page 866

Page 4246
Page 477
Page 5877
1. Disconnect the negative and positive battery cables from the battery. Then remove the battery
from the vehicle.
2. Remove the air bag module from the vehicle. Refer to the appropriate service manual for air bag
module removal procedures.
3. To assemble deployment trigger wires:
a. Obtain two wires at least 20 feet long.
(1) For driver side air bag:
Connect the two wires to the leads of the driver side SRS air bag adapter harness (listed in the
PARTS INFORMATION section of this bulletin).
(2) For passenger side air bag:
Connect the two wires to the leads of the passenger side SRS air bag adapter harness (listed in
the PARTS INFORMATION section of this bulletin).
b. Cover connections with insulation tape.
c. At the other end, temporarily connect the wires to each other (short circuit). This will help prevent
sudden unexpected deployment due to static electricity buildup.
Page 7204
RELAY VIEW
Headlight Washer Relay I

Page 1513
1996 Montero Service Manual, Volume 1, Page 11D-41 Correct the upper oil pan installation
Page 890
Page 3395
OPERATION
control module.
rotation.
Page 175
RELAY VIEW

Page 6606

Page 3530
Wire Color Codes
the marking color.

Page 7016
Wire Color Codes
the marking color.

Page 3937
1. After the snap ring is installed, check the operation of the first & reverse brake piston as follows:
2. By applying compressed air (400-800 kPa, 57-113 psi) into the oil hole of the transmission case
as illustrated, check that the first &
reverse brake piston slides smoothly.
D. Thrust bearing with race installation. (18)
1. Apply petrolatum to the thrust bearing with race and attach it so that the race side is oriented to
the transmission case side.
E. Thrust race / thrust bearing / thrust race installation. (12, 13 & 14)
1. Apply petrolatum to the thrust bearing, thrust race [28.8 mm (1.13 inch) in inner diameter] and
thrust race [27.6 mm (1.09 inch) in inner
diameter] and attach them to the rear planetary ring gear in the illustrated order and direction.
F. Planetary carrier thrust washers No. 1 and No. 2 installation. (9 & 10)
Service and Repair
Specifications

...................................................... 2,000 ± 100 Ohms
Page 6492


Page 4522
NO.: TSB-95-16-003
MODEL: All Models
VEHICLES AFFECTED
All models
PROCEDURE
CAUTION:

Page 2428
Wire Color Codes
the marking color.

Page 2181
pushed.

malfunction.
Page 2067
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Page 7193
3. Use a plastic trim stick to gently lift the outer edge of the moulding. Apply a bead of 3M 08661
silicone sealant or equivalent between the moulding and the glass.
4 Push the moulding down to ensure it is securely sealed onto the glass. If necessary, temporarily
apply masking tape to secure the moulding while the sealant sets.
5. Allow the sealant to set undisturbed for the length of time specified in the manufacturer's
instructions. Then remove tape if applied.
Windshield Moulding Sealant Cause Code: 990
Labor Operation No. 42312100 Time Allowance: 0.5 hr.
Warranty Coverage:36 months/36,000 miles. Special Warranty Information: Normal warranty

procedures apply.
Refrigerant Oil: Capacity Specifications CAPACITY
CAPACITY
120 C.C. 4.10 Oz. (US)

Power Steering Fluid: Capacity Specifications
Specification 1.12 qt (US)

Page 813


Page 311
6. Next, to observe the output of the wheel speed sensors, move the transfer shift lever to the "4H"
position, and the transmission control lever to the
"1" (M/T vehicles) or "D" position (A/T vehicles), and rotate the wheels.
NOTE: -
Check the connection of the sensor harness and connector before testing.
- The wave form measurements can also be taken while the vehicle is actually moving.
- The output voltage will be small when the wheel speed is low, and similarly it will be large when
the wheel speed is high.
- As the wheel speed sensor harness moves in conjunction with the movement of the front and rear
suspension, the wires might break while driving on rough roads, but may have continuity while
driving on normal roads. Accordingly, when measuring the wave pattern of the wheel speed sensor
output voltage, shake the sensor harness to simulate the special conditions of a rough road.
Resistance/Insulation Measurement
1. Check whether any metallic foreign material has adhered to the pole piece at the speed sensor
tip, and, if so, remove it. Also, check whether the
pole piece is damaged. Replace as necessary.
NOTE: The pole piece can become magnetized because of the magnet put into the speed sensor,
so that metallic foreign material easily adheres to
Specifications
Map Light: Specifications
Reading light ........................................................................................................................................
........................................................................... 8 W
Wheel Speed Sensor
Wheel Speed Sensor: Testing and Inspection Wheel Speed Sensor
Output Voltage Check
OUTPUT VOLTAGE MEASUREMENT
1. Check that the clearance between the wheel speed sensor and the rotor is within the standard
value of 0.2-1.0 mm (0.008-0.039 inches). 2. Raise up the wheels and release the parking brake. 3.
Disconnect the ABS-ECU connector and inspect the connector at the harness side.
CAUTION: Be sure to remove the connector double lock and insert the probe into the harness side.
Inserting it into the terminal side will result in a bad connection.
4. Rotate the wheel by hand to be measured at approximately 1/2-1 rotations per second and
check the output voltage using a voltmeter (AC mV
range) or an oscilloscope. Measure at the following terminals: a. The front LH sensor corresponds
to terminal Nos. 7 (+) and 20 (-) b. The front RH sensor corresponds to terminal Nos. 10 (+) and 23
(-) c. The rear LH sensor corresponds to terminal Nos. 9 (+) and 22 (-) d. The rear RH sensor
corresponds to terminal Nos. 8 (+) and 21 (-)
NOTE: The output voltage when measured with a volt meter is 70 mV or more. When measured
with a oscilloscope, 200 mV peak-to-peak or more.
5. If the output voltage is lower than the above values, the reason could be as follows:
- Excessive clearance between the wheel speed sensor pole piece and the rotor.
- Malfunction of wheel speed sensor. Adjust the wheel speed sensor or replace if necessary.
Page 4089
PARTS INFORMATION
Page 6827
Backup Lamp: Service and Repair
Rear Combination Light - Removal And Installation
Removal
Installation

Page 5035
Warranty Bulletin when this policy is to go into effect.
If you have questions regarding battery warranty or other vehicle warranty related issues, please
contact the Warranty Hotline at 1-800-380-2324 or via e-mail at WarrantyWebHotline@mmsa.com.
TOOL INFORMATION
Midtronics Micro530(TM) Warranty Information
The Midtronics Micro530(TM) Battery/Starting/Charging System Analyzer is warranted to be free of

defects in materials and workmanship for 2-years from date of receipt. Midtronics will, at their
option, repair the unit or replace the unit with a remanufactured tester. This limited warranty applies
only to the Midtronics Micro530(TM) Battery/Starting/Charging System Analyzer and does not
cover any other equipment, static damage, water damage, overvoltage, dropping the unit, or
damage resulting from extraneous causes including owner misuse. Midtronics is not liable for any
incidental or consequential damages for breach of this warranty. The warranty is void if the owner
attempts to disassemble the unit, or to modify the cable assembly.
Midtronics Micro530(TM) Service Information
To obtain service for the Midtronics Micro530(TM), contact Midtronics for a Return Authorization
number, and return the unit to Midtronics, freight prepaid, ATTN. ________ (Return Authorization).
Midtronics will service the tester and re-ship the next scheduled business day following receipt,
using the same type carrier and service as received. If Midtronics determines that the failure was
caused by misuse, alteration, accident, or abnormal condition of operation or handling, your
dealership will be billed for the repaired product and it will be returned freight prepaid with freight
charges added to the invoice. Battery testers which are beyond the warranty period are subject to
the repair charges in effect at that time. Optional remanufacturing service is available to return the
tester to like-new condition. Out-of-warranty repairs carry a 3-month warranty. Remanufactured
testers purchased from Midtronics are covered by a 6-month warranty. Additional questions can be
addressed directly to:
Midtronics Inc. 7000 Monroe Street Willowbrook, IL 60521 Telephone: (630) 323-2800
TOLL-FREE 1-800-776-1995
FAX: (630) 323-2844

Page 3431
Throttle Cable/Linkage: Service and Repair

Page 2146
Standard value:
oxygen sensor.
Page 1944
1997 Montero Service Manual Volume 1, Page 13A-58 Correct the description of the fuel pump
relay as shown:
Page 90
Horn Relay
Horn Relay - Check
Page 185
23, D3 - 10)
Page 1187
on actual vehicles.
Wire Color Codes
Page 5653
Ambient Temperature Sensor / Switch HVAC: Service and Repair
Outside Temperature Sensor - Removal And Installation
Removal
Installation

Service and Repair
Shift Interlock Cable: Service and Repair
Page 6591


Component Locations

Page 2454

Page 1616

Page 6167
1. Using isopropyl alcohol, degrease the body surface on which the side garnish is mounted.
2. If a new side garnish is used, peel off the release paper from the surfaces to which adhesive is
to be applied. If the old side garnish is to be reused,
remove adhesive as indicated. Then, apply double coated tape [5mm (.2 in.) wide and 1 mm (.04
in.) thick], dry adhesive to the areas shown in the illustration.
3. Install the side garnish so that the clips match the body holes.
NOTE: If the double-sided adhesive tape is difficult to affix during winter, etc., warm the bonding
surfaces of the body and the side garnish before affixing the tape.
Body: 40-60 degrees C(104-140 degrees F)

Page 2058

Page 6055
Radio And Tape Player (Part 1 Of 3) (Vehicles Without Amplifier)
Page 5440
1992-95 Montero Service Manual, Volume 1, page 37A-39 1996 & 1997 Montero Service Manuals,
Volume 1, page 37A-35 1998 & 1999 Montero Service Manuals, Volume 2, page 37A-36 2000
Montero Service Manual, Volume 2, page 37A-32
Page 3821
Service and Repair
Page 6556
Door/Trunk Ajar Indicator/Lamp: Description and Operation
- This warning light comes on the door is either open or not completely closed.
Page 2826
OPERATION
Page 542

SENSOR VIEW

Upper Ball Joint
Ball Joint: Service and Repair Upper Ball Joint
REMOVAL

Page 2023
Page 3555
Component View
Page 5387
a. Power steering gear box installation (8).
1. Install the power steering gear box to the frame after inserting the power steering gear box
mainshaft into the joint assembly. 2. Before connecting fluid lines, fill the steering gear box with the
power steering fluid.
NOTE: Operational steps after installation as follows: -
Fill power steering fluid.
- Bleed Power steering fluid line.

Locations

Page 755


Page 810

Page 5393
c. Bearing installation (5).
Apply specified automatic transmission fluid to the outside of the bearing, and then use the special
tools to press the bearing into the valve housing. Specified fluid: Automatic transmission fluid
"DEXRON II"
d. Seal ring installation (8).
When installing the seal ring, press it firmly into the valve groove.
e. Cage/ball/bearing race/main shaft installation (9, 10, 11 & 12).
1. Apply specified automatic transmission fluid to the valve body.
2. Wrap vinyl tape around the serrated part so that the oil seal won't be damaged when the valve
body is installed to the valve housing. 3. Install the valve body to the valve housing.
4. Align the cage's hole and the channel in the main shaft, and insert two or three balls. 5. Insert
the remainder of the balls into the cage's hole while pressing the ball with the bearing race.
6. When installing the main shaft, connect it to the valve housing while pressing the bearing race so
that the balls do not come out.
Page 6833
Grounding Markings

Page 6918

Page 3575
Wire Color Codes
the marking color.


SRS Maintenance
them with new ones.
A. WARNING
injury.
Specifications
Synchronizer Ring: Specifications
Clearance Between Outer Synchronizer Ring Back Surface And Gear:
Limit .....................................................................................................................................................
................................. 0.3 mm (0.012 inch)
Page 4641

Page 3317
RELAY VIEW

Page 1744
Fan Blade: Service and Repair
Refer to the illustration for the service procedure.

Page 6345
1998 Montero Service Manual, Volume 2, Page 80-14 Correct the description as shown:
Page 5609
Tires: Application and ID
GENERAL INFORMATION
A full size spare tire has been adopted as the spare tire in all models.
Tire
Size: 265/7OR15 110H.

Page 1762

Resistance/Torque
Design Thermistor

Page 5475
Page 2715
RELAY VIEW

Page 3241
Page 6793

Front Steering Knuckle: Technical Service Bulletins Steering - Cautions for Steering Angle
Adjustment
No: TSB-00-37A-001
DATE: October, 2000
MODEL: See Below

adjustment.
MANUAL REVISIONS
Page 2781

Page 724
Condenser Fan: Testing and Inspection
INSPECTION
- Check the condenser fan for crushing or other damage.
- Check the condenser's high-pressure hose and pipe installation parts for damage or deformation.
- Check the condenser fan shroud for damage.
INSPECTION OF CONDENSER FAN MOTOR
When battery voltage is applied to the terminal (2) and terminal (1) is grounded, check that the
condenser fan motor turns.
Page 1319
Page 4474
INSPECTION
Standard value:
Locations
Tachometer Connector: Locations
COMPONENT VIEW VIEW
Engine Speed Detection Connector A

Page 4643

Page 756
on actual vehicles.
Wire Color Codes
Page 2700
Wire Color Codes
the marking color.

Page 4909
Brake Master Cylinder: Service and Repair Master Cylinder Bleeding
CAUTION: Use only the specified brake fluid. Never mix the specified brake fluid with other fluids
as it will influence the braking performance significantly. The specified brake fluid is DOT 3 or DOT
4.
The master cylinder used has no check valve, so if bleeding is carried out by the following
procedure, bleeding of air from the brake pipeline will become easier. (When brake fluid is not
contained in the master cylinder.) 1. Fill the reserve tank with brake fluid. 2. Keep the brake pedal
depressed. 3. Have another person cover the master cylinder outlet with a finger. 4. With the outlet
still closed, release the brake pedal. 5. Repeat steps 2 - 4 three or four times to fill the inside of the
master cylinder with brake fluid.
Brakes - Revised Rear Rotor
Rear: Technical Service Bulletins Brakes - Revised Rear Rotor
NO.: TSB-98-27-003 DATE: June, 1998 MODEL: See Below
SUBJECT: CHANGED ABS ROTOR - SERVICE MANUAL REVISION
PURPOSE This bulletin has information about a change to the rear rotor for the anti-lock brake
system (ABS) equipped 1997 Montero and 1997 Montero Sport vehicles built after June 2, 1997.
The ABS rotor is changed to a sheet metal rotor and is not interchangeable with the rotor used on
vehicle built before the change over date. Related service procedures and specifications for this
new-style rotor have changed and there is new special tool information.
AFFECTED VEHICLES 1997 Montero built after June 2, 1997 1997 Montero Sport built after June
2, 1997
AFFECTED SERVICE MANUALS 1997 Montero Service Manual, Volume 1, Pages 27-2, 3, 4, 6,
19, 24 1997 Montero Sport Service Manual, Volume 2, Pages 27-18, 23, 26, 29, 30, 55

Page 5137
Page 3270
Wire Color Codes
the marking color.


Resistance/Torque

Page 2456

Page 6580

- Clock Spring
- Air Bag Module
Service Precautions
table.
SRS-ECU Connector
Page 2061
Wire Color Codes
the marking color.

Page 6714

Page 5533
NOTE:
Locations
CONTROL UNIT VIEW
A/C Control Unit B

Specifications
Shifter Transfer Case: Specifications
SPECIFIED LUBRICANTS
- Hypoid Gear Oil SAE 75W-85W Conforming to API Classification GL-4 Used For Transfer Control
Lever Assembly O-Ring.
SEALANTS AND ADHESIVES
- 3M ATD Part No. 8663 or Equivalent Used For Transfer Control Lever Assembly Gasket.
- 3M STUD Locking Part No. 4170 or Equivalent Used For Transfer Control Lever Assembly
Mounting Bolt.
Page 5340

Page 6224
Teck Line.
Specifications
Transfer Case Cover: Specifications
Chain Cover .........................................................................................................................................

........................................... 36 Nm (26 ft. lbs.) Oil Pool Cover ............................................................
.................................................................................................................. 9 Nm (78 inch lbs.) Rear
Cover ...................................................................................................................................................
................................... 36 Nm (26 ft. lbs.) Side Cover .........................................................................
............................................................................................................. 19 Nm (14 ft. lbs.)
Page 5493
B. Lower ball joint and knuckle/upper ball joint and knuckle disconnection. (5 & 7)
CAUTION: 1. Support the lower arm with a jack when removing the knuckle from the lower ball joint
or the upper ball joint. 2. After the knuckle has been removed, lower the jack slowly. 3. Use a cord
to bind the special tool closely so that it will not become separated. 4. The nut should only be
5. Insert the special tool securely.
INSPECTION
1. Check the needle bearing for wear or damage 2. Check the knuckle for cracks or bends 3.
Check the knuckle spindle for wear or pounding.
INSTALLATION
NOTE: Operational steps after installation as follows: 1. Install front hub.

Page 3901
piston No. 2.
remove.
remove.
remove.
INSPECTION
Specifications
Crankshaft Position Sensor: Specifications
Torque 7 ft.lb
Page 3743
PARTS INFORMATION
Page 2797
Grounding Markings

Specifications
Torque 7 ft.lb
Torque Specifications
Differential Case: Specifications Torque Specifications
TORQUE SPECIFICATIONS
Ring gear bolts: ...................................................................................................................................

................................ 137 - 167 Nm (101 - 123 ft. lbs) Companion flange: ..........................................
....................................................................................................................................... 216 Nm (159
ft. lbs) Carrier bearing cap bolts
.............................................................................................................................................................
55 - 65 Nm (40 - 47 ft. lbs) Bearing lock plate bolts ............................................................................
................................................................................................. 19 Nm (14 ft. lbs) Air pipe banjo bolt .
..............................................................................................................................................................
...................... 15 Nm (11 ft. lbs) Air pipe retainer bolts .......................................................................
............................................................................................................. 9 Nm (7 ft. lbs) Rear
differential lock detection switch
...................................................................................................................................................... 36
Nm (27 ft. lbs)
Page 170
Specifications
Intake Air Temperature Sensor: Specifications

Page 4517
Fluid - Transfer Case: Fluid Type Specifications
SPECIFIED LUBRICANTS Transfer Oil: Hypoid Gear Oil SAE 75W-85W Conforming to API
Classification GL-4
Page 778
OPERATION
control module.
rotation.
Page 2939
position sensor.

Page 6513


Page 1924

Page 6967

Engine - Pinging Condition
Fuel: All Technical Service Bulletins Engine - Pinging Condition
SOURCE: Mitsubishi Tech Talk Article October 2004
APPLIES TO: All models
SERVICE TIP:
When diagnosing an engine pinging condition, always check for engine carbon deposits, which
may have occurred due to fuel grade or quality and/or the customer's driving style. If necessary,
clean carbon deposits from the pistons and combustion chamber. Recommend to customers to
always use the correct grade of fuel for their model vehicle.
Page 2988
Wire Color Codes
the marking color.

Precautions

PURPOSE
AFFECTED VEHICLES

Page 2231

Page 584

Page 3655
identification colors on the vacuum hose at the vacuum tank connection.
B. Vacuum hose/solenoid valve assembly installation. (5 & 6)
Install the vacuum hose and solenoid valve assembly so that the colors of the identification marks
are matched.
Page 4575
Check the continuity between the black connector terminal on the top of the transfer case and the
transfer case.
Transfer control lever position: Continuity 2H: No Continuity 4H: Continuity
High Range/Low Range Detection Switch Check
Check the continuity between the white connector terminal on the side of the transfer case and the
transfer case.
Transfer control lever position: Continuity 4HLc: Continuity N (between 4HLc and 4LLc): No
Continuity 4LLc: Continuity
Low Range Detection Switch Check

transfer case.
Transfer control lever position: Continuity 4HLc: No Continuity 4LLc: Continuity

Locations

Page 1510
1992-96 Engine (Overhaul) Service Manual, Page 11E-138 Correct the upper oil pan installation
Page 6579
driver injury.
Page 5014
1997 and 1998 Montero service manuals, Volume 1, page 23A-45
Page 4842
shown.
Page 2785
Throttle Position Sensor: Electrical Specifications Sensor Resistance/Torque/Voltage
Sensor Resistance/Torque/Voltage
Between terminals 1 and 4 3.5 - 6.5 K ohms
Torque 1.5 ft.lb

Page 1669
speed.
Page 6496
Accessory Socket
Page 6565
Fuel Gage Simple Inspection

Page 3034

control module.
Page 4153
REMOVAL
INSTALLATION
Page 6477
Wire Color Codes
the marking color.

Page 5436
1996 & 1997 Montero Service Manuals, Volume 1, page 37A-18 1998, 1999, & 2000 Service
Manuals, Volume 2, page 37A-18
Page 4524
Synchronizer Hub: Service and Repair

DISASSEMBLY
INSPECTION
Synchronizer Ring And Synchronizer Cone
1. Combine the inner and outer synchronizer rings and cone with the drive sprocket and measure
the dimension A in the illustration. If the
dimension A is less than the limit, replace them as a set.
NOTE: Scratches may be found on the cone surface in the rotating direction these are produced by
the liners of the synchronizer rings and do not mean the malfunction. Therefore, the parts need not
be replaced if the above-mentioned clearance is satisfied.
ASSEMBLY

Specifications
Torque 7 ft.lb
Fuel System - EVAP DTC's & Check Engine Light
Fuel Filler Cap: Technical Service Bulletins Fuel System - EVAP DTC's & Check Engine Light
SOURCE: Mitsubishi Tech Talk Article November 2004
TITLE: Loose Gas Caps & Check Engine Light
SERVICE TIP:
A gas cap which is not properly tightened after refueling can cause EVAP DTCs and check engine
light illumination. If you encounter related EVAP DTCs, check the cap first. Remember, a loose gas
cap is not a warranty repair. Also, very little effort is required on later model vehicles to properly
secure the gas cap.
Page 1433
Valve Guide: Testing and Inspection
Measure the clearance between the valve guide and valve stem. If the limit is exceeded, replace
the valve guide or valve, or both.
Intake
Standard Value: 0.02 - 0.05 mm (0.0008 - 0.0020 inch) Limit: 0.10 mm (0.004 inch)
Exhaust
Standard Value: 0.04 - 0.07 mm (0.0016 - 0.0028 inch) Limit: 0.15 mm (0.006 inch)
Cooling System - Water Pump Leak Inspection
Water Pump: Technical Service Bulletins Cooling System - Water Pump Leak Inspection
No: TSB-10-14-001
DATE: March, 2010
MODEL: All models
SUBJECT: WATER PUMP LEAK INSPECTION CRITERIA
PURPOSE
This TSB provides inspection criteria for determining a leaking water pump. Following this
procedure will prevent unnecessary replacement.
When examining a vehicle for coolant loss, a complete cooling system diagnosis is required. The
presence of dried coolant residue is not an indication of a defective water pump. Water pump
clearances vary with engine temperature and new water pumps can leak coolant due to the
presence of manufacturing residue (e.g. casting sand), which is flushed from the pump over time.
Because of these and other factors, some evidence of coolant residue near the drain hole is
normal.
AFFECTED VEHICLES All models and years
PROCEDURE
NOTE:
On some models, the vehicle must be raised on a lift to view the underside of the water pump and
its surrounding area.
Some models require the removal of the timing belt cover to inspect the water pump. Refer to the
service manual for details.
INSPECTION
1. The engine should be at normal operating temperature.
2. Inspect the underside of the water pump and the surrounding area.
a. If there is no coolant residue, the water pump is not leaking and should not be replaced.
b. If dry coolant residue is seen, clean the area to prevent confusion during future inspections.
Page 6851

Page 1335
Connecting Rod: Specifications
Connecting Rod Cap Nut Torque 34 ± 2 Nm +90 - 100 deg.

INSPECTION
Using Scan Tool
HARNESS INSPECTION
NOTE:
Page 4439
Component View
Page 6815

Page 6531
B. CAUTION: SRS
frame.
F. CAUTION: SRS
G. WARNING: SRS
H. Danger: Poison.
medical attention.
J. CAUTION: SRS
key.
Page 4501
Grounding Markings

Page 3180
- Example 2
normal.
Page 3603
Removal
Installation
Page 917
Page 1628
Page 6501
Cigarette Lighter: Service and Repair
Cigarette Lighter - Removal And Installation
Removal
Installation

Page 821
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Hazard Warning Switch: Testing and Inspection
Hazard Light Switch
1. Remove the hazard light switch from the meter bezel.
Hazard Light Switch Inspection - Chart

Page 736

INSPECTION
Using Scan Tool
HARNESS INSPECTION
NOTE:
Specifications
Engine Accessory Bracket: Specifications
Accessory Mount Stay Bolts
M8 ........................................................................................................................................................
......................................... 23 Nm (17 ft. lbs.) M10 ..............................................................................
................................................................................................................. 49 Nm (36 ft. lbs.)
Page 6776

Specifications
Outside Temperature Display Sensor: Specifications
Outside temperature sensor resistance
20° C (68° F) Approx. 1,200 Ohm
40° C (104° F) Approx. 500 Ohm


SRS Maintenance
them with new ones.
A. WARNING
injury.
Page 6818


Page 967
Page 445
Wire Color Codes
the marking color.

Page 2438

Page 2596
Page 231

Page 704

Page 5956
Lighting Monitor/Key Reminder/Seat Belt Warning Buzzer

Locations

Page 2302
Grounding Markings

Service and Repair
Headlamp Bulb: Service and Repair
Replaceable Bulb Replacement
1. Remove the air cleaner assembly and radiator reserve tank. (When replacing the right headlight
for turbo vehicles). 2. Remove the sealing cover by turning it counterclockwise.
Replaceable Bulb Replacement
3. Remove the bulb socket by turning it counterclockwise, and then remove the bulb.
CAUTION: Do not touch the surface of the bulb with hands or dirty gloves. If the surface does
become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing.
4. Install the sealing cover securely after the bulb replacement, or the lens will be out of focus, or
water will get inside the light unit.
Page 145
Page 4677
Page 4106
Page 6543

HARNESS INSPECTION
Page 3502
Grounding Markings

Page 5773
unit.
DISCHARGING THE SYSTEM
Use the refrigerant recovery unit to discharge refrigerant gas from the system.
unit.
SUPPLYING OF OIL IN THE AIR CONDITIONING SYSTEM
Too little oil will provide inadequate compressor lubrication and cause a compressor failure. Too
much oil will increase discharge air temperature. When a 10PA15 compressor is installed at the
factory, it contains 120 cubic cm (4.1 fl.oz.) of refrigerant oil. While the air conditioning system is in
operation, the oil is carried through the entire system by the refrigerant. Some of this oil will trapped
and retained in various pants of the system. When the following system components are changed,
it is necessary to add oil to the system to replace the oil being removed with the component.
Compressor oil: ND-OIL 8
Quantity:
Evaporator: 40 cubic cm (1.4 fl.oz.) Condenser: 40 cubic cm (1.4 fl.oz.) Suction hose: 10 cubic cm
(0.3 fl.oz.) Receiver: 10 cubic cm (0.3 fl.oz.)
Locations
RELAY VIEW

Specifications
ABS Light: Specifications
Anti-lock braking system warning light ................................................................................................
...................................................................... 1.12 W
Brake Warning Indicator: Diagram Information and Instructions
Page 5194
Dedicated Fuse
Page 5565
Remote Controlled Variable Shock Absorber System (Part 2 Of 2)
Page 2172
Grounding Markings

Page 2003

Locations

SENSOR VIEW

Page 6797
on actual vehicles.
Wire Color Codes
Page 2039

Page 1972
23, D3 - 10)
Page 5292
Page 816
Page 2506

SENSOR VIEW

Page 803
Removal
Installation
Page 3975

Page 2197
OPERATION
control module.
rotation.
Page 7034
Parking Lamp: Description and Operation
- When the lighting switch is set to the TAIL or HEAD position, the tail light relay contact closes to
turn the tail light relay on.
- Current flows via dedicated fuse No. 5 and the tail lights, parking lights, side marker lights and
license plate light illuminate.
Page 6466
Audible Warning Device: Testing and Inspection Lighting Monitor Buzzer Check
Lighting Monitor Buzzer Check
1. Apply battery positive voltage between terminals 2, 8 and 10. 2. Check that the buzzer sounds
intermittently when terminal 4 is grounded.
Page 4228
Grounding Markings

Page 4851
shown.
Maintenance Required Lamp/Indicator: Diagram Information and Instructions
Page 2600
STEP 2. Check for an open circuit or a short-circuit to ground between the idle air control motor
- Idle air control motor connector: Disconnected OK: STOP NG: Repair the harnesses. (A1 - 4, A3 -
17, A4 - 5, A6 - 18)
IDLE AIR CONTROL MOTOR CHECK Checking Operation Sound
(1) Check that the operating sound of the stepper motor can be heard over the idle air control
motor when the ignition switch is turned to the ON
position (without starting the engine).
(2) If no operating sound can be heard, check the stepper motor drive circuit. (If the circuit is good,
a defective stepper motor or engine control
module is suspected.)
Checking Coil Resistance
(1) Disconnect the idle air control motor connector and connect the special tool (test harness). (2)
Measure the resistance between terminal (2) (White clip of the special tool) of the connector at the
idle air control motor side and terminal (1)
(red clip) or terminal (3) (blue clip).
Standard value: 28 - 33 Ohms [at 20°C (68°F]
(3) Measure the resistance between terminal (5) (green clip of the special tool) of the connector sat
the idle air control motor side and terminal (6)
(yellow clip) or terminal (4) (black clip).
Standard value: 28 - 33 OHMS [at 20°C (68°F)

Page 1495
Engine Oil: Fluid Type Specifications
Temperatures below 38°C (100°F)
..................................................................................................................................................... SAE
5W-30 Preferred Temperatures above -18°C (0°F) ............................................................................
......................................................................................... SAE 10W-30
NOTE Use only engine oils displaying the Engine Oil Licensing and Certification System (EOLCS)
certification mark on the container. If these oils are not available, those with an American
Petroleum Institute (API) classification SH EC II or SH/CD EC II can be used. The SAE grade
number indicates the viscosity of the oil. A proper SAE grade number should be selected according
to ambient temperature.
Page 3815
Clutch: Specifications Overdrive Clutch
Bushing Inner Diameters (Limit):
Overdrive Direct Clutch Drum

................................................................................................................................................ 27.11
mm (1.067 inch) Overdrive Planetary Gear
........................................................................................................................................................
11.27 mm (0.444 inch)
Overdrive Direct Clutch:
Disc Thickness (Limit)

............................................................................................................................................................
1.84 mm (0.0724 inch) Return Spring Free Length
................................................................................................................................ Approximately
15.8 mm (0.622 inch) Piston Stroke
.......................................................................................................................................................
1.85-2.15 mm (0.0728-0.0846 inch)
Page 6511
Grounding Markings

Page 3968
OPERATION
Page 5734
Evaporator Core: Specifications
............................................................................................................ 40 cubic cm (1.40 fl. oz.)
Page 6642
Grounding Markings

Specifications
............................................................... 1.4 (74) W

Page 2821

Page 1191
Maintenance Required Lamp/Indicator: Testing and Inspection
Reset Switch
After checking is completed, use the reset switch (located at the rear of the combination meter) to
switch off the warning light. Note that the warning light bulb should be removed after 100,000 miles
are registered.
NOTE: If the speedometer is to be replaced, set the new odometer to the same reading as the
odometer being removed.
Engine - Using Low-Quality Engine Oil
Engine Oil: Technical Service Bulletins Engine - Using Low-Quality Engine Oil
SOURCE: Mitsubishi Tech Talk Article January/February 2005
TITLE: Using Low-Quality Engine Oil
SERVICE TIP:
It is very important that ONLY the recommended API SJ, API SL, or API SM engine oil be used in
Mitsubishi vehicles. Lower quality engine oils can seriously damage engine components (excessive
deposits, sludging, higher than normal component wear). Increased wear and deposits can also
lead to excessive emissions.
Customers should be instructed to use ONLY engine oil which meets the manufacturer's
requirements. Warranty coverage could be denied for failures attributed to improper engine oil
usage.
Page 546
Grounding Markings

Page 6372

Locations
Page 6223

- Clock Spring
- Air Bag Module
Service Precautions
table.
SRS-ECU Connector
Locations

Page 2622
Page 4691
OPERATION
Page 4706
Leak Detection Solenoid: Diagram Information and Instructions
Page 3570

Page 4164
REMOVAL
1. Remove under cover. 2. Drain gear oil. 3. Follow removal steps outlined in illustration.

Page 2732
HARNESS INSPECTION
NOTE: -
- 92)
control module. -
(A3 - 90, A7 - 19)

Specifications
Engine Mount: Specifications
M8 ........................................................................................................................................................
............................................... 22 Nm (16 ft. lbs.) M10 ........................................................................
............................................................................................................................. 41 Nm (30 ft. lbs.)
M12 ......................................................................................................................................................
.............................................. 75 Nm (54 ft. lbs.)
Page 2020


Page 3738
Page 4504
on actual vehicles.
Wire Color Codes
A/T - DTCs 29, 30, 31, & 32 Set Criteria Corrections
Transmission Speed Sensor: Technical Service Bulletins A/T - DTCs 29, 30, 31, & 32 Set Criteria
Corrections
NO.: TSB-98-23-013 DATE: August, 1998 MODEL: 1996-98 Montero
SUBJECT: A/T DTCS 29-32 SET CONDITIONS - SERVICE MANUAL REVISION
PURPOSE Set conditions for diagnostic trouble codes (DTCs) 29, 30, 31, and 32 are incorrectly
specified in the troubleshooting procedures on the affected service manual pages. This bulletin
contains corrections for input and output shaft speed sensor pulse output specifications for these
DTCs.
AFFECTED VEHICLES 1996-98 Montero models with automatic transmission
AFFECTED SERVICE MANUALS 1996 Montero, Volume 1, pages 23A-19, 23A-20, and 23A-36.
NOTE:
Illustrations 2 through 4 of this bulletin correct speed sensor pulse output specifications for the
troubleshooting procedures described in TSB-97-23-001, which contains further updates to 1996
Montero A/T troubleshooting.
1997 Montero, Volume 1, pages 23A-15, 23A-16, 23A-17, and 23A-36
1996 Montero, Volume 1, page 23A-19, Refer to page 9 of TSB-97-23-001.

Page 3715
Component View
Fluid - M/T: Capacity Specifications
Specification ........................................................................................................................................
........................................................................ 3.3 qts.
Page 5034
Use the BATTERY TEST WORKSHEET form when testing batteries and record all necessary
information. A pad of the worksheet forms was shipped with the initial Midtronics Micro530(TM) kit.
A copy is also shown.
If the tested battery is still covered under an MMSA warranty and the test indicates that the battery
is "bad" and should be replaced, document the test results on the repair order. The Midtronics
Micro530(TM) can output a "Warranty Code" with each battery tested. The Micro530(TM) has
software that generates a unique 10-digit encrypted warranty test code when the unit's "CODE"
button is pressed while viewing the test results. This alphanumeric warranty test code will be
unique every time the tester is used.
Even with the quick results the Micro530(TM) provides, your dealership will still be allowed to claim
the 0.2 hour "Battery Test" labor operation time along with the 0.3 hour battery replacement time
whenever you encounter a failed warranty-covered battery.
At a future date, the battery test results code will be required for every warranty replaced battery or
the claim will be rejected. You will be notified by a
Page 2920
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A2 - 87)
- 92)

SRS Maintenance
them with new ones.
A. WARNING
injury.
Specifications
.................................................................... 1.12 W
Page 1316
NOTE ^
system.

Page 160

Page 1985


Page 2684
Page 5841
Teck Line.
Locations

SENSOR VIEW

Page 3049
HARNESS INSPECTION
control module. -
- 86)
- Ground)

Page 573
Wire Color Codes
the marking color.

Page 3019

Page 2178
OPERATION
control motor.
Page 1215
Wheels: Application and ID
GENERAL INFORMATION
Wheel Type: Aluminum type. Size: 15 x 7JJ. Amount of wheel offset: 10 mm (.39 inch). Pitch Circle
Diameter (P.C.D.): 139.7 mm (5.5 inch).
Specifications
Door Lamp: Specifications
Door light .............................................................................................................................................
........................................................................... 5 W
NO.: TSB-95-16-003
MODEL: All Models
VEHICLES AFFECTED
All models
PROCEDURE
CAUTION:

Precaution
PURPOSE
AFFECTED VEHICLES

Page 4179
H. Side bearing inner race installation. (26)
Use the special tool to press-fit the side bearing inner races into the differential case.
I. Final drive gear backlash adjustment. (-) Adjust the final drive gear backlash by the following
procedure:
1. Install side bearing spacers which are thinner than those removed to the side bearing outer
races, and then install the differential case
assembly to the gear carrier.
NOTE: Select side bearing spacers with the same thickness for both the drive pinion side and the
drive gear side.
2. Push the differential case assembly to one side, and then measure the clearance between the
gear carrier and the side bearing adjusting
spacer with a feeler gage.
3. Measure the thickness of the side bearing adjusting spacers on one side, select two pairs of
spacers which correspond to that thickness plus
one half of the thickness plus 0.05 mm (0.002 inch), and then install one pair each to the drive
pinion side and the drive gear side.
Page 4701
Page 124
Download Error

Overdrive Clutch
Clutch: Service and Repair Overdrive Clutch
DISASSEMBLY
INSPECTION
Antenna Motor: Symptom Related Diagnostic Procedures
E-1 Motor Antenna Won't Extend or Retract
Chart E-1
Motor antenna won't extend or retract.
Clean and polish the surface of the antenna pole.
E-2 Motor Antenna Extends and Retracts But Does Not Receive
Page 3791
INSPECTION
the ground.
Page 4989
SENSOR VIEW
Speed Sensor (front) Z
Speed Sensor (rear) V

Page 6688

Page 6154

procedures apply.
Page 5700
Control Assembly: Service and Repair Heater Control Assembly Removal and Installation
REMOVAL SERVICE POINTS

Page 5522

Page 1904
MAIN MENU
IMPORTANT
connectors.

the main menu.
Page 1009
Spark plug ID
NGK .....................................................................................................................................................
................................................................PFR5J-11
Denso ..................................................................................................................................................
............................................................PK16PR-P11
Page 2858
Manifold Pressure/Vacuum Sensor: Testing and Inspection
INSPECTION
Using Scan Tool

HARNESS INSPECTION
Manifold differential pressure sensor connector: Disconnected OK: GO TO STEP 2 NG: Repair the
harness. (A2 - 92)
STEP 2. Check for open-circuit, or short-circuit to ground, between the engine control module and
the manifold differential pressure sensor -
Manifold differential pressure sensor connector: Disconnected
(A1 - 74)
STEP 3. Measure the sensor feed voltage to the manifold differential pressure sensor. -
- Ignition switch: ON Voltage: 4.8 - 5.2 V OK: STOP NG: Replace the engine control module.
Page 2829
INSPECTION
Using Scan Tool
HARNESS INSPECTION
harness (A2 - 92)
- 77)
A/T - Perform Cooler Flow Test When Replacing A/T
Transmission Cooler: Technical Service Bulletins A/T - Perform Cooler Flow Test When Replacing
A/T
No: TSB-98-23-004 DATE: April, 1998 MODEL: See below
SUBJECT: REPLACEMENT A/T FLOW TEST
PURPOSE
Automatic transmissions requiring replacement may have particles in the ATF trapped in the
radiator transmission cooler, causing a plugged or restricted condition. Any vehicle that receives a
new (remanufactured) or repaired automatic transmission must have the transmission cooler in the
radiator backflushed and a flow test performed.
If the transmission cooler is plugged or restricted, it can cause the replacement transmission to fail.
This bulletin contains instructions for flow testing the replacement transmission's cooler.
AFFECTED VEHICLES
All models equipped with automatic transmission
PROCEDURE
Before transmission installation is complete, the A/T radiator cooler and lines must be backflushed.
Use Transmission Cooler Flusher (OTC p/n 108-MLR-6906A) or equivalent.
On models equipped with an auxiliary oil cooler, it must be backflushed separately.
After backflushing, verify that the backflush was adequate by performing the following radiator
transmission cooler and auxiliary oil cooler flow test:
FLOW TEST (with the new transmission installed)
IMPORTANT:
The transmission must be at normal operating temperature for the flow test.
1. If a graduated container is not available, prepare one as follows:
Using a large clean plastic container, pour in one quart of liquid (such as oil or water). Mark the
1-quart level. Then add another quart and mark the 2-quart level. Discard the liquid, and use the
empty marked container for the flow test.
2. To prevent damaging the transmission during the test, overfill the transmission by one quart of
ATF.
3. Connect the transmission output line to the cooler inlet nipple. Connect the other cooler hose to
the cooler outlet nipple. Place the other end of the hose in the graduated container.
4. With the line from the transmission cooler placed in the container, start the engine in Neutral and
watch for clean ATF flow (no bubbles or foam).
Continue until the ATF flows clean and the fluid level reaches the 1-quart mark.
5. When the fluid reaches the 1-quart mark, start the timer for the flow test.
Page 6124
Page 6917
Grounding Markings

Page 5298
Idler Arm: Testing and Inspection
STARTING TORQUE CHECK
1. Give 10 hard swing to the idler arm. 2. Measure the idler arm swing resistance with a spring
scale.
Standard value:
Starting torque: 0.3 - 2.0 Nm (3 - 17 inch lbs.) Turning torque: 2.3 - 15.4 N (.5 - 33.9 lbs.)
Page 6562
Fuel Gauge: Description and Operation
- When the ignition switch is turned to the "ON" position, the fuel gage is activated.
- When there is much fuel, the unit's resistance is small and the current flowing in the circuit is
great, so the gage's indicator indicates in the F area.
- When there is little fuel, the unit's resistance is high and the current flowing in the circuit is small,
so the gage's indicator indicates in the E area.
Specifications
Brake Caliper: Specifications
Cylinder Inner Diameter 1.69 in
Assembly Bolt 65 ft.lb
Brake Hose Flare Nut 11 ft.lb
Bleed Screw 6 ft.lb
Guide Pin 54 ft.lb
Lock Pin 54 ft.lb

Page 4953
RELAY VIEW

Page 720

Engine Oil: Capacity Specifications
Engine Oil Refill
With Filter ............................................................................................................................................

........................................................... 5.5 Qts.(5.2L)
Note: Includes 0.5 Qts. Oil Filter and 0.5 Qts Oil Cooler
Page 823
Removal
Installation
Page 7070
Page 3021

Corrections
DTCs.
NOTE:

Page 4113
7. Put a new valve body gasket No. 2 on the plate.
8. While pushing the gaskets and the plate against the upper valve body, put the upper valve body
on the lower valve body.
CAUTION: Be careful not to drop the check balls and strainers from the upper valve body.
9. Insert the 25 bolts from the upper valve body side.
A: 38 mm (1.50 inch) B: 20 mm (0.79 inch) C: 28 mm (1.10 inch)
10. Install the manual valve to the lower valve body.
11. Install the detent spring and cover by tightening the bolt.
Page 2220
OPERATION
Page 327

Resistance/Torque
Design Thermistor

Adjustments
Trunk / Liftgate: Adjustments
BACK DOOR
ADJUSTMENT OF BACK DOOR
1. To adjust the fit of the door panel and the body, loosen the door striker mounting screw and
move the striker. 2. Adjust the linking of the striker and the door latch by increasing or decreasing
the thickness of the shim under the striker.
Page 7209
RELAY VIEW

Page 2480
Grounding Markings

Page 1014
injection.
CAUTION: -
100 kPa (14 psi).
NOTE: -
Page 4173

Page 1832


Page 398
Page 2948
Page 4593
Page 4780
SENSOR VIEW

Page 6090
Wire Color Codes
the marking color.

Forward Clutch
Clutch: Specifications Forward Clutch
Disc Thickness (Limit) .........................................................................................................................

.......................................... 1.84 mm (0.0724 inch) Drum Bushing Inner Diameter (Limit)
.......................................................................................................................................... 24.07 mm
(0.948 inch) Piston Stroke
..............................................................................................................................................................
2.90-4.29 mm (0.1141-0.1689 inch) Return Spring Free Length
................................................................................................................................... Approximately
11.55 mm (0.4547 inch)
Service and Repair
Heater Core: Service and Repair
INSPECTION
- Check the operation of dampers and link mechanism.

- Check the heater core for clogging and water leakage.
Starter Drive/Bendix: Testing and Inspection
1. While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one
direction, but should not rotate in opposite direction.If
clutch does not function properly, replace overrunning clutch assembly.
2. Inspect pinion for wear or burrs. If pinion is worn or burred, replace overrunning clutch assembly.
If pinion is damaged, also inspect ring gear for
wear or burrs.
Page 123
memory.
III. Error List

Page 4825
CAUTION: -
Protect the caliper body with a cloth, and then blow compressed air through the brake hose to
remove the piston boot and the piston.
- Blow compressed air gently.
DOT 4 brake fluid.
Connecting Rod: Specifications Service Specifications
2. Loosely tighten each nut to the bolt. 3. Then tighten the nuts alternately to a torque of 34 Nm (25
ft. lbs.) to install the cap properly. 4. Make a paint mark on the head of each nut. 5. Make a paint
mark on the bolt end at the position 90 - 100° from the paint mark made on the nut in the direction
of tightening the nut. 6. Give a 90 - 100° turn to the nut and make sure that the paint mark on the
nut and that on the bolt are in alignment.
CAUTION: -
Page 6015
CONTROL UNIT VIEW
Specifications
Torque 7 ft.lb
Page 2991
Page 565
SENSOR VIEW

Specifications
Brake Fluid: Specifications
Fluid Specification Conforming to DOT 3 or DOT 4

Page 5407
Page 5218
Centralized Relay
Page 5989
Page 3944
Part 2 Of 3
Input Speed Sensor
INSPECTION
Specifications
Sensor Bolt
Torque 7 ft.lb
Page 5053
RELAY VIEW
Generator Relay B
Page 4303
Wheel Bearing: Service and Repair
BEARING REPLACEMENT
Page 5809
Removal
Installation

Page 5406
Page 6085

Page 6801

Locations
Number One Cylinder: Locations
Number One Cylinder
Page 781
follows.
that position.
Page 3375
Ohms
Page 2903
Page 2076
SENSOR VIEW

Page 5145
Grounding Markings

Page 685
Page 1405
Piston Ring: Service and Repair
1. Fit the oil ring spacer into the piston ring groove.
Specifications
Solenoid: Specifications
Solenoid Value Resistance:
At 20° C (68° F) ...................................................................................................................................

................................................... 36 - 46 ohms
Coil Spring Seat: Customer Interest Differential Whine - Revision
PURPOSE
Symptom
Cause
Remedy
NOTE:
Page 1831

Page 2138
Wire Color Codes
the marking color.

Page 759
OPERATION
control motor.
Page 3847
DISASSEMBLY

Page 3850
Locations

Page 4716
INSPECTION
Standard value:
Page 171
fuel pump relay.
Page 5079
REMOVAL
INSPECTION
Specifications
Parking Brake Lever: Specifications
Lever Stroke ........................................................................................................................................
.............................................................. 4 - 6 notches
Page 3962
Grounding Markings

Page 919
Page 4745
Acceleration/Deceleration Sensor: Testing and Inspection Less Scan Tool
1. Disconnect the G-sensor connector and connect tool No. MB991348, or equivalent, between the
terminal of the disconnected connector. 2. Turn the ignition switch to "ON" and take a reading of
the output voltage between terminals Nos. 2 and 3. The standard value is 2.4 - 2.6 volts.
3. With the special tool still connected, secure the G-sensor so that the FRONT mark on the sensor
mounting surface is facing straight down, and
then take a reading of the output voltage between terminals Nos. 2 and 3. The standard value is
3.4 - 3.6 volts.
4. If the voltage is outside the standard value, after checking to be sure that there is no abnormality
in the power supply and earth wires, replace the
G-sensor.
Page 4850
1997 Montero Sport Service Manual, Volume 1, Page 27-29 Change the indicated page as shown,
Page 3237

Page 5674
INSPECTION
curve in the graph.
TESTING
replaced.
Coolant: Capacity Specifications
Cooling Capacity 10.0 qt (US)
Including heater and coolant reserve tank.

Page 6964
RELAY VIEW
Ignition Key Hole Illumination Light Timer E

Specifications
Torque 7 ft.lb
Page 6945
Page 1386
Harmonic Balancer - Crankshaft Pulley: Specifications

Page 7222
Wiper Relay: Locations Rear Intermittent Wiper Relay

Page 6900
Grounding Markings

Page 555
harness. (A3 - B1)
(A1 - Ground)
harness. (A2 - 89)
Windshield: Customer Interest Wind Noise At Upper Windshield
PURPOSE
AFFECTED VEHICLES
1992-97 Montero
PROCEDURE

Page 3559
STEP 2. Check for continuity between the ignition power transistor unit and the ignition coil. -
Ignition coil connector: Disconnected
- Ignition power transistor connector: Disconnected OK: GO TO STEP 3 NG: Repair the harnesses.
(A1 - D6, B1 - D6, C1 - D6)
STEP 3. Measure the power supply voltage of the ignition coil. -
Ignition power transistor: Disconnected
- Ignition switch: ON Voltage (V): Battery positive voltage OK: GO TO STEP 4 NG: Repair the
harnesses. (DII, D12, D13 - Ignition coil)
STEP 4. Check for an open circuit or a short-circuit to ground between the ignition power transistor
(D1 - 11, D2 - 23, D3 - 10, D5 - 51)
(D4 - Ground)
Page 1557
on actual vehicles.
Wire Color Codes
Page 3750
INSPECTION
Standard value:
Specifications
Turn Signal Indicator: Specifications
Turn signal indication light ...................................................................................................................
.............................................................. 3.4 (158) W
NOTE: The values in the parentheses denote SAE trade numbers.

Page 681

Page 3761
INSPECTION
transfer case.
transfer case.
transfer case.

Page 1734
Coolant: Fluid Type Specifications
Coolant Type High quality ethylene glycol base anti-freeze/coolant
Mitsubishi Part No. 0103044 (DIA-QUEEN LONG-LIFE COOLANT)
Coolant Conentration 40 - 50 %
Fuel Supply Line: Testing and Inspection
- Check the fuel hoses and pipes for cracks, bends, deformation, deterioration or clogging.
- Check the fuel filter for clogging or damage.
- Check the canister for clogging or damage.

Part 1 Of 3
Page 3855
drum.
illustration.
Direct Clutch
Page 3581
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Page 5907
2. When disconnecting the connector of the clock spring from the air bag module, press the air
bag's lock toward the outer side to spread it open. Use
a screwdriver to pry gently as shown in the figure at the left, to remove the connector.
CAUTION: 1. Wait disconnection the air bag module-clock spring connector, take not to apply
excessive force to it.
2. The removed air bag module should be stored in a clean, dry place with the pad cover face up.
Step 4: Steering Wheel Removal
CAUTION: Do not hammer on the steering wheel. Doing so may damage the collapsible column
mechanism.
1. When installing the new air bag module and clock spring, refer to "INSPECTION"
CAUTION: Dispose of an air bag module only according to the specified procedure.
2. Connect the battery (-) terminal.
3. Connect the scan tool to the data link connector then check diagnostic codes.
4. Turn the ignition key to the "ON" position. 5. Conduct diagnostic test using the scan tool to
ensure entire SRS operates properly.
Page 7123
on actual vehicles.
Wire Color Codes
Page 7011

Page 3984
Correction
PURPOSE
AFFECTED VEHICLES
PROCEDURE
NOTE:
Page 3323
relay as shown:
Page 368
Removal
Installation

Page 3396
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A1 - 92)
control module. -
Page 737


Page 4047
Transmission Cooler: Technical Service Bulletins A/T Oil Cooler - Backflush Alternative
NO: TSB-99-23-011 DATE: October, 1999 MODEL: All A/T models
SUBJECT: OIL COOLER BACKFLUSH ALTERNATIVE
PURPOSE
When repairing or replacing an automatic transmission, be sure to thoroughly flush the A/T oil
cooler and verify that the ATF flows through the cooler at a rate of at least one quart in 20 seconds
or less. If the oil cooler is not flushed before installing the new A/T unit, the restricted oil cooler
could cause severe damage to the transmission.
There are now two accepted methods of backflushing the A/T oil cooler. MMSA's preferred method
is to use a flushing tool such as OTC p/n 108-MLS-6906A, available from OTC or DES (call
1-800-727-6672).
However, if a flushing tool is unavailable, an acceptable alternative is to use an aerosol A/T Oil
Cooler Flush solution, listed in the PARTS INFORMATION section of this bulletin.
This bulletin describes how to use aerosol A/T Oil Cooler Flush solution as an alternative oil cooler
backflushing method when a flushing tool is not available.
AFFECTED VEHICLES
All models equipped with automatic transmission
PROCEDURE
Page 6635
The cost for the odometer resetting will be billed to your dealership. For reimbursement when the
speedometer is covered under the vehicle warranty, this expense can be claimed as a sublet repair
along with the labor removing and replacing the unit and the shipping. Refer to warranty bulletin
WB 2001-012.
This bulletin is for information only, not warranty authorization. For complete warranty information
concerning new speedometer odometer resetting, see Warranty Bulletin WB 2001-012. If you have
any questions regarding this service or the procedures, please contact the Warranty Hotline at
800-380-2324.
Page 337
Page 341

Page 525

SENSOR VIEW

Page 2483
on actual vehicles.
Wire Color Codes
Page 1451
1997 Montero Service Manual, Volume 1, Page 11B-34 Delete the indicated illustration and add
the new illustration and caution as shown.
Page 4424

Page 3358
OPERATION
Page 1793
Temperature Gauge: Description and Operation
- When the ignition switch is turned to the "ON" position, the engine coolant temperature gage is
activated.
- When the engine coolant temperature is high, the unit's resistance is low and there is a great flow
of current in the "H" area.
- When the engine coolant temperature is low, the unit's resistance is high and there is a small flow
of current in the circuit, so the gage's indicator indicates in the "C" area.
Page 2961
Ignition switch-ST
HARNESS INSPECTION
module. -
NOTE: -

Page 4447
Wire Color Codes
the marking color.

Page 631
OPERATION
Page 4086
Engine - Valve Noise at Start-up
Lifter / Lash Adjuster: Customer Interest Engine - Valve Noise at Start-up
NO.: TSB-95-11-001
MODEL: V6 and DOHC Models
SUBJECT: VALVE NOISE AT START-UP
BACKGROUND INFORMATION On V6 and DOHC models, it is normal to hear a valve noise (a

"ticking" sound) during the first two minutes after engine start-up. However, vehicles that are
overdue for oil change or have not been started for a long period of time may experience the noise
for longer than two minutes. The noise is caused by air in the high pressure chamber inside the
automatic valve lash adjusters.
Replacing valve lash adjusters will probably not eliminate valve noise. This bulletin contains
procedures to bleed air out of the adjusters and to confirm that the adjusters do not require
replacement.
NOTE:
For Eclipse models with 420A engine, refer to the "Lash Adjuster Check" on page 110-12 in the
1996 Eclipse service manual. Do not perform the procedures in this bulletin.
VEHICLES AFFECTED All V6 and DOHC models
PROCEDURE
If valve noise (a "ticking" sound) lasts more than two minutes after engine start-up, perform the
following steps in order:
1. Check the engine oil level and quality, and correct as necessary. Start the engine. If the valve
noise continues for longer than two minutes after start-up, continue with Step 2.
2. Warm the engine to normal operating temperature. Increase idle speed gradually to 3,000 rpm,
then back down to normal idle speed. Repeat this process several times (maximum of ten times). If
the valve noise continues, stop the engine. Inspect the automatic valve lash adjusters as described
in Steps 3 and 4 below.
CAUTION:
Wear protective gloves and use care to protect yourself from hot engine components.
3. Remove the oil cap on the rocker cover and listen for the source of the noise. If it seems to be
coming from the valve lash adjusters, proceed to Step 4. Otherwise, refer to section 11 of the
appropriate service manual for further engine diagnosis to determine the cause of the noise.
5. Using finger pressure, push down on the rocker arm over the head of each valve lash adjuster.
NOTE:
Fuel Pump Relay: Diagram Information and Instructions
Page 3503

Page 1259
9. Temporarily tighten the rocker shaft with bolts at the condition that all the intake valve rocker
arms do not push the valves.
10. Insert the rocker shaft spring from above and mount it at right angles to the plug guide.
NOTE: Before installing the exhaust rocker arms and rocker arm shaft, mount the rocker shaft
spring.
11. Remove the lash adjuster holder used to hold the lash adjuster in position.
12. Check to ensure that the flat side of the rocker shaft is directed as shown in the illustration.
13. Install the camshaft oil seal as shown.

Page 2591
Grounding Markings

Specifications
Standard ..............................................................................................................................................
....................................................................................................................... 890 kPa (127 psi)
.................................................................................................................................................. 100
kPa (14 psi)
Diagrams
Page 3074

Page 7026

Page 2986


Page 3667
Part 3 Of 3
Page 4638
CONTROL UNIT VIEW
Page 3525

Page 4339
Drive/Propeller Shaft: Fluid Type Specifications
SPECIFIED LUBRICANTS
Oil Seal Lip: Hypoid Gear Oil SAE 75W-90 or 75W-85W Conforming to API Classification GL-4.
Sleeve Yoke: Hypoid Gear Oil API Classification GL-4 or Higher SAE Viscosity 80W, 75W-85W.
Locations
Positive Crankcase Ventilation Valve: Locations


SRS Maintenance
them with new ones.
A. WARNING
injury.
Page 158
relay as shown:
Page 4187
1. Connect an air hose, pressure gage and air regulator, for adjusting the compressed air pressure,
to the actuator pipe. 2. Adjust the compressed air pressure with the air regulator until the pressure
gage shows a pressure of approximately 25 kPa (4 psi.).
3. Use the special tool to gently turn only the side gear of one side of the axle 1/4 - 1/2 turns.
NOTE: -
The lock will not operate when both side gears turn together, even when air pressure is supplied.
The side gear on one side of the axle must be turned so that the clutch will mesh (lock).
- To unlock, shut supply of air pressure, and gently turn the side gear on one side of the axle 1/4 -
1/2 turns.
4. Measure the rotation torque of the companion flange, and check the lock condition and free
condition of the rear differential.
Rear differential operation
Locked: Companion flange doesn't turn at 49 Nm (36 ft. lbs.) [1,111 N (248 lbs.)] Free: Companion
flange turns at less than 49 Nm (36 ft. lbs.) [1,111 N (248 lbs.)]
Disassembly
Page 588
on actual vehicles.
Wire Color Codes
Page 2879
Page 7001
Wire Color Codes
the marking color.

Page 6235
Headliner Repair Nature Code: 86Z
Cause Code: 440
Labor Operation No. 52410100 Time Allowance: 1.0 hrs.
Warranty Coverage: 3 years/36,000 miles. Special Warranty Information: Normal warranty

procedures apply.
Page 572
on actual vehicles.
Wire Color Codes
Page 1592


Page 5996
Page 2905
INSPECTION
Using Scan Tool

HARNESS INSPECTION
(A1 - 37)
control module.
Page 3536
HARNESS INSPECTION
NOTE -
(A1 - D6, B1 - D6, C1 - D6)
(D1 - 11, D2 - 23, D3 - 10, D5 - 51)
Page 6773
activated.
Specifications
Overdrive Assembly: Specifications
Overdrive Direct Clutch Drum

................................................................................................................................................ 27.11
mm (1.067 inch) Overdrive Planetary Gear
........................................................................................................................................................
11.27 mm (0.444 inch)
Overdrive Support Assembly Return Spring:
Free Length
.......................................................................................................................................................
Approximately 18.6 mm (0.732 inch)
Overdrive Support Mounting Bolt

........................................................................................................................................................ 26
Nm (19 ft. lbs.)
Specifications
Clutch Fluid: Specifications
Note:
Specification Conforming to DOT3 or DOT4

Page 184
(A1 - D6, B1 - D6, C1 - D6)
(D1 - 11, D2 - 23, D3 - 10, D5 - 51)
(D4 - Ground)
Page 3590

Specifications
Sensor Bolt
Torque 7 ft.lb
Accessory Socket Relay Check
Auxiliary Power Outlet: Testing and Inspection Accessory Socket Relay Check
Accessory Socket Relay Check - Chart
1. Remove the accessory socket relay from the junction block. 2. Apply battery positive voltage to
Speaker: Customer Interest Audio System - Speaker Static/Buzzing/Inoperative
PURPOSE
Symptom/Condition
^ Static
^ Popping
^ Crackle
^ Buzzing
^ Rattle
^ Distorted sound
CHECKLIST REQUIRED
AFFECTED VEHICLES
PROCEDURE
Page 3508
OPERATION
Page 6532
driver injury.
Page 6799
Volt Meter Gauge: Electrical Diagrams
Multi Meter
Page 6571
A (Float point "F") ................................................................................................................................

........................................................ 119.3 (4.69) in. B (Float point "E") ..............................................
........................................................................................................................................ 255.0
(10.03) in.
Page 1575
Intake Manifold: Diagrams

Page 2624
INSPECTION
Using Scan Tool

HARNESS INSPECTION
harness. (A2 - 92)
(A1 - 74)
Page 1280
condition.
NOTE
CAUTION
Page 6983


Page 6973
Ignition Key Hole Illumination Light

Page 1907
Page 5262


Drive/Propeller Shaft: Customer Interest Differential Whine - Revision
PURPOSE
Symptom
Cause
Remedy
NOTE:
Page 4350
3. Install the snap ring on the opposite side, and measure the clearance of the snap ring groove
with a thickness gage.
CAUTION: Always use snap rings of equal thicknesses on both sides.
4. If the clearance exceeds the standard value, adjust by changing the thickness of the snap ring.
Page 5905
Clockspring Assembly / Spiral Cable: Service and Repair
CAUTION:
Do not drop the air bag module or clock spring or allow contact with water, grease or oil. Replace it
if a dent, crack, deformation or rust are detected.
2. The air bag module should be stored on a flat surface and placed so that the pad surface is
facing upward.
Do not place anything on top of the air bag modules.
4. Do not expose the air bag module to temperature over 93°C (200°F). 5. After deployment of an
air bag, replace the clock spring with a new one. 6. Wear gloves and safety glasses when handling
an air bag that has deployed. 7. An undeployed air bag module should only be disposed of in
accordance with the procedures.
- After setting the steering wheel and the front wheels, to the straight ahead position, remove the
ignition key.
Air Bag Module And Clock Spring
Clock Spring Removal Steps
1. Negative (-) battery cable connection 2. Air bag module (Driver's side) 3. Cap 4. Steering wheel
5. Column cover lower 6. Clock spring and body wiring harness connection 7. Clock spring -
Pre-installation
Air Bag Module Removal Steps (Driver's side)
1. Negative (-) battery cable connection 2. Air bag module (Driver's side) -
Air Bag Module (Passenger's side)

Page 2002
Grounding Markings

EGR Control Solenoid: Diagram Information and Instructions
Page 448
Brake Light Switch: Testing and Inspection
The stop light switch is in good condition if there is no continuity when the plunger is pressed in,
and if there is continuity when the plunger is released outward. For models equipped with cruise
control system, check for continuity at stop light switch connectors A and B.
Page 159
Specifications
Ignition Coil: Specifications Coil Resistance
Coil Resistance
Primary 0.74 - 0.90 ohms
Secondary 20.1 - 27.3 K ohms

Locations

Page 146
Page 4118
10. While pushing the pressure regulator valve sleeve with a finger, install the seat.
CAUTION: The seat must engage with the same groove of the primary regulator valve sleeve as
before.
11. Install the 1-2 shift valve, spring and plug as illustrated. 12. While pushing the plug, install the
seat. 13. Apply Automatic Transmission Fluid (ATF) to three new O-rings and install them to the
solenoids respectively.
14. Put the shift solenoids No. 1, No. 2 and lock up solenoid as illustrated and tighten the bolts.
15. Check that the three seats are installed as illustrated. 16. Install the check ball. 17. Install the
steel ball and the check valve.
Page 2554
Page 3011
position sensor.

Page 281
RELAY VIEW

Rocker Arm Assembly: Technical Service Bulletins Valve Lash Adjuster Noise - Troubleshooting
Procedures

PROCEDURES
Starion
shown.
PROCEDURES

checks:
NOTE: (1)
adjuster.
Page 4059
Page 336
Wire Color Codes
the marking color.

Page 6772
Temperature Gauge: Application and ID
Engine coolant temperature gage is a Cross Coil Type Gage.
Page 904
OPERATION
Page 4403
on actual vehicles.
Wire Color Codes
Page 3157
Page 1237
Wheel Fastener: Service and Repair
REPLACEMENT
1. Remove the caliper assembly and secure it with wire so that it does not fall. 2. Remove the
brake disc.
3. Use the special tool to remove the hub bolt.
CAUTION: Insert the spacer of thickness of approximately 3 mm between the special tool
(MB991618) and the dust cover to protect the dust cover.
4. Using the hub nut, tighten the hub bolt to install it.
Page 6723
Rheostat
Rheostat
Page 3324
relay as shown:
Locations

Component Inspection
Fuel Tank Pressure Sensor: Testing and Inspection Component Inspection
1. Disconnect the fuel tank differential pressure sensor connector and connect the special tool
between the terminals of the disconnected connector. 2. Turn the ignition switch to ON and take a
reading of the following output voltage.
Between terminals (2) and (3). Standard value: 2.0 - 3.0 V

Specifications
Power Steering Pressure Switch: Specifications Operating Pressure
Operating Pressure
Close Pressure 213 - 284 psi
Open Pressure 100 - 171 psi

Page 506

Page 3916
D. Clutch flange installation. (4)
1. install the clutch flange to the overdrive direct clutch drum so that the flange's convex side faces
up as illustrated.
Page 2485
Page 2962

control module.
Page 3436

Part 1 Of 3
Specifications
Timing Belt: Specifications
1997 CA vehicles, replacement at 60,000 mile intervals is recommended but not required. On all
1997 models, replace every 100,000 miles (if not previously replaced). On 1998 & later CA, CT, MA
vehicles replacement at 60,000 mile intervals is recommended but not required. On all 1998 & later
models replace every 100,000 miles (if not previously replaced).
Specifications
Sensor Bolt
Torque 7 ft.lb
Page 922
PARTS INFORMATION
Page 4678

Page 3006
on actual vehicles.
Wire Color Codes
Page 3720

Page 2822


Page 4619
OPERATION CHECK
pressure equalizes.

Intake Air Plenum: Testing and Inspection
Check the intake manifold plenum for damage and cracks and replace it if any defects are found.
Page 4688
on actual vehicles.
Wire Color Codes
Parking Lamp: Diagram Information and Instructions
Page 4357
Universal Joint: Application and ID
GENERAL INFORMATION
Type: Cross type.
Lubrication method: Nipple type.
Journal Outer Diameter:
Front propeller shaft: 14.689 mm (0.5783 inch) Rear propeller shaft: 18.300 mm (0.7205 inch)
Page 5710

Page 1438
Valve Seat: Testing and Inspection
Assemble the valve, then measure the valve stem projection between the end of the valve stem
and the spring seating surface. If the measurement exceeds the specified limit, replace the valve
seat. Standard value: 49.30 mm (1.9409 inch)
Limit: 49.80 mm (1.9606 inch)

Page 6889
Grounding Markings

Page 2134
Grounding Markings

Page 4445


Page 6522
SENSOR VIEW

Page 2348
speed.
ABS - Front Speed Sensor Rotor Design Change
Wheel Speed Sensor: Technical Service Bulletins ABS - Front Speed Sensor Rotor Design
Change
NO.: TSB-97-26-003 DATE: June, 1997 MODEL: 1997 Montero
SUBJECT: FRONT ABS SPEED SENSOR ROTOR MODIFICATIONS - SERVICE MANUAL

REVISION
PURPOSE The design of the front ABS speed sensor toothed rotor on affected vehicles has been
changed since November, 1996 production. The new toothed rotors are made of sheet metal and
have four mounting bolts. The brake disc bearing surfaces have been modified to accommodate
the new rotors.
AFFECTED VEHICLES 1997 Montero models equipped with anti-lock brake system (ABS)

Page 1909
8. If the PCM has already been reprogrammed with this database, this message displays and
reprogramming will not continue.
It is possible that the MUT-III main harness is not properly connected to the VCI unit.
reprogramming.
Page 7106
Turn Signal Lamp: Description and Operation
1. In normal operating condition
- When the ignition switch is turned to the ON position, battery positive voltage is applied through
the hazard light switch to the turn-signal and hazard flasher unit.
- When the turn-signal light switch is placed in the L.H. (or R.H.) position, Tr1 in the flasher unit
turns on, causing the relay contacts in the flasher unit to close. This causes the L.H. (or R.H.)
turn-signal light and turn-signal indicator light to illuminate.
- At the same time, the capacitor is charged through R2 up to the lower limit as set by COM3.
- As soon as the capacitor is fully charged, the output from COMS is inverted, turning off Tr1. This
opens the relay contacts and, as a result, the L.H. (or R.H.) turn-signal light and turn-signal
indicator light switch off.
- At the same time as Tr1 turns off, the capacitor starts discharging. As soon as the capacitor
completes discharging, the COM3 output is inverted again, causing Tr1 to turn on. This causes the
L.H. (or R.H.) turn-signal light and turn-signal indicator light to illuminate.
- This sequences of operations occurs repeatedly, causing the L.H. (or R.H.) turn-signal light and
turn-signal indicator light to flash on and off.
2. When one bulb is burnt
- When either one of the turn-signal light bulbs switches off, it causes the resistance of the entire
light circuit to increase, resulting in a smaller voltage drop at R1 in the flasher unit.
- This smaller voltage drop is sensed and the lower voltage limit set by COM3 is raised, thus
shortening the time required by the capacitor before it is fully charged.
- As a result, the on-off cycle of Tr1 becomes shorter with the result that the light flashes on and off
more quickly.
Page 5945
Page 4887
Brake Hose/Line: Service and Repair Less ABS
REPLACEMENT
1. Drain the brake fluid into a suitable container. 2. Refer to the illustration and remove the sections
of brake hose/brake pipe sa necessary.
CAUTION: Do not disassemble the load sensing proportioning valve. Its performance depends on
the load of the spring.
3. Ensure complete hydraulic system bleeding. See: Brake Bleeding/Service and Repair
Page 1119
Refrigerant: Fluid Type Specifications TYPE
TYPE
R-134a (HFC-134a)
Page 5467
Control Arm Bushing: Service and Repair Lower Arm Bushing (B) Replacement
1. Use the special tools to remove bushing (B) from the lower arm.
2. Coat bushing (B) and the lower arm with soap solution, and then use the special tool to press-fit
bushing (B) into the lower arm, taking care not to
twist or tilt bushing (B).
NOTE: Press-fit the bushing again from the opposite side to equalize bushing projections at both
ends.
Specifications
Idler Arm: Specifications
Idler Arm Ball Joint Breakaway Torque

.............................................................................................................................. 0.3 - 2.0 Nm (3 -
17 inch lbs.) Idler Arm Turning Torque
....................................................................................................................................................... 2.3
- 15.4 N (.5 - 33.9 lbs.) Idler Arm Support Nut .....................................................................................
........................................................................... 54-64 Nm (40-47 ft.lbs.)
Page 5970
Seat Belt Reminder Lamp: Description and Operation
- This indicator illuminates for four to eight seconds when the ignition switch is at the ON position,
even if the driver has fastened his seat belt.
Page 6088


Page 6986
License Plate Lamp: Electrical Diagrams
Tail, Parking, Side Marker And License Plate Lights (Part 1 Of 2)

Page 689
follows.
that position.
Input Speed Sensor
INSPECTION
Specifications
Valve Body: Specifications
Mounting Bolt .......................................................................................................................................

................................... 10 Nm (86.4 inch lbs.) Upper Bolt ...................................................................
.................................................................................................................. 7 Nm (60 inch lbs.)
Page 5200

Page 1453
Valve: Specifications
DIMENSIONS
Clearance Between Valve Guide And Valve Stem
Intake
Standard Value
......................................................................................................................................... 0.02 - 0.05
mm (0.0008 - 0.0020 inch) Limit ..........................................................................................................
......................................................................... 0.10 mm (0.004 inch)
Exhaust
Standard Value
......................................................................................................................................... 0.04 - 0.07
mm (0.0016 - 0.0028 inch) Limit ..........................................................................................................
......................................................................... 0.15 mm (0.006 inch)
Face Angle ..........................................................................................................................................

.............................................................. 45 - 45.5° Margin
Intake
Standard Value ....................................................................................................................................

................................. 1.0 mm (0.039 inch) Limit ..................................................................................
................................................................................................... 0.5 mm (0.019 inch)
Exhaust
Standard Value ....................................................................................................................................

................................. 1.2 mm (0.047 inch) Limit ..................................................................................
................................................................................................... 0.7 mm (0.028 inch)
Stem Diameter
Intake ...................................................................................................................................................
....................................... 6.0 mm (0.236 inch) Exhaust .......................................................................
................................................................................................................ 6.0 mm (0.236 inch)
Stem Projection
Standard Value ....................................................................................................................................

................................. 49.30 mm (1.9409 inch) Limit ............................................................................
......................................................................................................... 49.80 mm (1.9606 inch)
Valve Total Length
Intake
Standard Value
.............................................................................................................................................................
112.30 mm (4.4213 inch) Limit ............................................................................................................
................................................................. 111.80 mm (4.4016 inch)
Exhaust
Standard Value
.............................................................................................................................................................
114.11 mm (4.4925 inch) Limit ............................................................................................................
................................................................. 113.61 mm (4.4728 inch)
Page 5479
Page 1995
- Example 2
normal.
Page 1654
b. Line up the timing marks of the front bank camshaft sprockets. c. Line up the timing marks of the
rear bank camshaft sprockets.
CAUTION: Since the camshaft sprocket readily turns because of spring action, use care to make
sure that your finger is not caught.
d. Line up the timing marks of the crankshaft sprockets. e. Install the timing belt on each sprocket
in the following sequence:
1. Install the timing belt on the crankshaft sprocket and then on the idler pulley, while tightening it to
prevent slackness. 2. Install the timing belt on the front bank camshaft sprocket. 3. Install the timing
belt on the water pump pulley, while taking up the slack. 4. Install the timing belt on the rear bank
camshaft sprocket. 5. Install the timing belt on the tensioner pulley.
6. Lightly press the tensioner pulley against the belt and temporarily tighten the center bolt. 7.
Check to see that the timing marks of all the sprockets are in alignment.
California
Catalytic Converter: Service and Repair California

Page 3782
are matched.
Page 4341
Drive/Propeller Shaft: Application and ID
GENERAL INFORMATION
Type: 2 joint propeller shaft.
Length (Joint to Joint) x Outer Diameter
Front ....................................................................................................................................................
.............. 713.0 x 50.8 mm (28.10 x 2.00 inch) Rear ...........................................................................
......................................................................................... 736.5 x 75.0 mm (29.00 x 2.95 inch)
Page 1958
fuel pump relay.
Page 1829


Page 11
With Scan Tool
Acceleration/Deceleration Sensor: Testing and Inspection With Scan Tool
1. Unload the vehicle and move it to a horizontal surface. 2. Connect the scan tool to the data link
connector.
3. Start the engine and check that the ABS warning light illuminates for a brief period before turning
"OFF." 4. Check that the G sensor output voltage is within the standard value range. The standard
value is 2.4 - 2.6 volts. 5. If the G sensor output voltage is not within the standard value range,
check the installation condition of the G sensor. If there is a loose bolt,
deformation of the G sensor bracket, etc., carry out the necessary repair. If the problem is not
repairable, replace the G sensor.
Page 5286
Locations

Page 5457
INSPECTION
1. Check ball joint breakaway torque.
a. After shaking the ball joint stud several times, install the nut to the stud and use the special tool
joint. Standard value: 0.8-3.5 Nm (7-30 inch lbs.)
b. When the measured value exceeds the standard value, replace the ball joint. c. When the
excessive play. If so, it is possible
1. Remove the dust cover.

Valve Body Assembly
Specifications
Valve Spring: Specifications
DIMENSIONS
Free Height:
Standard Value ....................................................................................................................................

........................................ 51.0 mm (2.01 inch) Limit ...........................................................................
................................................................................................................. 50.0 mm (1.97 inch)
Load/Installed Height
............................................................................................................................................... 267
N/44.2 mm (60 lbs./1.740 inch) Out-Of-Square:
Standard Value ....................................................................................................................................

........................................................ 2° Or Less Limit ..........................................................................
.............................................................................................................................. Maximum 4°
Page 6379
NOTE:
WARNING:
NOTE:
Page 3595
Wire Color Codes
the marking color.

Page 6411
Cruise Control Servo: Testing and Inspection
1. Remove the actuator. 2. Apply negative pressure to the actuator with the vacuum pump and
check that the holder moves more than 35 mm (1.38 in.). In addition, check
that there is no change in the position of the holder when negative pressure is maintained in that
condition.
3. First install the actuator, and then inspect and adjust the cruise control cable.
Page 2423

Page 6541

Page 2083
on actual vehicles.
Wire Color Codes
Page 1967
Component View
Service and Repair
Heater Core Case: Service and Repair
INSPECTION

Electronic Compass, Oil Pressure Gage and Voltage
Meter
Oil Pressure Gauge: Service and Repair Electronic Compass, Oil Pressure Gage and Voltage
Meter
Electronic Compass, Oil Pressure Gage And Voltage Meter - Disassembly And Reassembly
Disassembly Steps
1. Meter garnish 2. Meter grass 3. Window plate 4. Voltage meter 5. Oil pressure gage 6.
Connector bracket 7. Electronic compass 8. Back-light bulb 9. Meter case
Disassembly
Reassembly

Locations

Page 3858
ASSEMBLY
B. Clutch flange installation. (3)
1. Install the clutch flange to the direct clutch drum so that the flange's convex side is oriented to
the rear side.
1. Install the snap ring so that the end gap of the snap ring is not aligned with the inner cutout of
the direct clutch drum.
Forward Clutch
Page 6856
Wire Color Codes
the marking color.

Page 2311
Page 4176
2. Use the special tool to tighten the companion flange to the specified torque.
3. Use the special tools to measure the drive pinion rotation torque (without the oil seal).
Standard value:
New (with anti-rust agent): 0.3 - 0.5 Nm (2.6 - 4.3 inch lbs.) New/reused (gear oil applied): 0.15 -
0.25 Nm (1.3 - 2.2 inch lbs.)
4. If the drive pinion rotation torque is not within the standard value range, adjust the preload by
replacing the drive pinion front shim(s)
or the drive pinion spacer;
NOTE: When selecting the drive pinion rear shims, if the number of shims is large, reduce the
number of shims to a minimum by selecting the appropriate drive pinion spacers. Also, select the
drive pinion spacer from the following two types.
Height of drive pinion spacer:
With identification color: 56.67 mm (2.231 inch) No identification color: 57.01 mm (2.244 inch)
5. Remove the companion flange and drive pinion again.
With oil seal:
1. After setting the drive pinion rear bearing inner race, use the special tool to drive the oil seal into
the front lip of the gear carrier.
Page 2911

Page 5026
RELAY VIEW
Starter Relay E
Page 6667
Wire Color Codes
the marking color.

Page 3446
pushed.

malfunction.
Locations

Page 3514
Removal
Installation
Page 2221
Ignition switch-ST
HARNESS INSPECTION
module. -
NOTE: -

Page 5732
7. Shake the bottle of Mitsubishi Cooling Coil Coating well, then attach it to the assembled
applicator kit as shown in the illustration.
8. Close the passenger side air vents. Open the passenger side door. Be sure you are wearing
safety goggles, a face mask (3M: 07185 is recommended), and gloves.
9. With the engine still idling, tan on HI speed, and the mode on recirculate, insert the applicator
nozzle in through the recirculate door opening (or on late model Galant and Eclipse with HVAC
filter, through the filter opening). Spray the coating product in short bursts, with a few seconds
between each burst.
NOTE:
This procedure wets the entire air entry passage and may create a fog from the air outlet vents
which will enter the passenger compartment. This will NOT stain or harm the vehicle's interior.
Be sure to use to use goggles and breathing protection (3M: 07185). DO NOT inhale vapors.
10. When the coating product bottle is empty, shut oft the vehicle's ignition switch. Let the vehicle
sit for 30 minutes. This allows the liquid to flow over the evaporator coil fins and case assembly,
covering most of the contaminated area.
11. After 30 minutes, again with the mode set to recirculate, fan on HI, and temperature control to
maximum heat, start the engine and let it run at idle speed for 30 minutes. Make sure the windows
are open. This will dry and cure the Mitsubishi Cooling Coil Coating onto the evaporator coil.
12. Reinstall the glove box (and HVAC filter if applicable).
13. Reconnect the A/C clutch electrical connection (the receiver/drier pressure switch connector or
the clutch connector).
Page 5891
Clock Spring
3. Check for continuity between the No.1 connector of the clock spring and connectors No. 3 and 4
4. Align the paint mark of the SRS check harness connector No.4 with the notch in clock spring
connector No.2 (arrow in the illustration) to
connect the connectors Nos.2 and 4.
5. Check continuity between the terminals 22 and 23 of the SRS check harness connectors No.5.
Page 3363
connected.)
connector.
increased.
Page 642

Page 5238
Alignment: Testing and Inspection
1. Place the front wheels on turning radius gauge and measure steering angle.
Standard value:
Inside wheel: 29° 40' to 32° 40' Outside wheel: 29° 45'
2. If the steering angle is outside the standard value, check the toe-in, and then adjust the steering
angle with the stopper bolt.
Page 5092
Low Fuel Lamp/Indicator: Diagram Information and Instructions
Page 1766

Page 3045
on actual vehicles.
Wire Color Codes
Page 2165
INSPECTION
Using Scan Tool

HARNESS INSPECTION
(A1 - 37)
control module.
Page 375
Page 676

SENSOR VIEW

Page 1724
Water Pump: Specifications
Mounting Bolt .......................................................................................................................................

............................................... 24 Nm (17 ft. lbs.)
Page 3602
increased.

Page 5287
1997 Montero Service Manual, Volume 1, Page 37A-8 Add the new steering adjustment caution
statement as shown.
Page 5933
CAUTION:
Removal Steps
work.
Page 1228
2. Install the lock washer. If the lock washer holes are not aligned with the lock nut holes, move the
lock nut within a range of not more than
20° until the holes are aligned.
3. Loosen the lock nut approximately 30 to 40 degrees to adjust the front hub's turning resistance
and play in the axial direction so that they
are at the standard values.
Standard value: 0.3-1.3 Nm (2.6-11.3 inch lbs.)
[Spring scale reading 5-18 N (1.1-4.0 lbs.)]
NOTE: If adjustment is not possible, the bearing may be incorrectly installed; check and repair if
necessary. The lubrication condition should also be checked.
4. Install the lock washer. If the lock washer holes are not aligned with the lock nut holes, loosen
the lock nut to align them.
B. Drive shaft end play adjustment. (-)
After installing the shim and snap ring, check the drive shaft end play by the following procedure: 1.
Install the shim and snap ring to the drive shaft. 2. Push the drive shaft in by hand toward the
knuckle until they touch. 3. Measure the clearance between the drive flange and the shim with a
feeler gage as shown in the illustration.
Standard value: 0.4-0.7 mm (0.016-0.028 inch)

Specifications
Piston Ring: Specifications
DIMENSIONS
End Gap
No. 1 Ring
Standard
................................................................................................................................................... 0.30 -
0.45 mm (0.0118 - 0.0177 inch) Limit ..................................................................................................
................................................................................... 0.8 mm (0.031 inch)
No. 2
Standard
................................................................................................................................................... 0.45 -
0.60 mm (0.0177 - 0.0236 inch) Limit ..................................................................................................
................................................................................... 0.8 mm (0.031 inch)
Oil Ring
Standard
................................................................................................................................................. 0.10 -
0.35 mm (0.0039 - 0.0138 inch) Limit ..................................................................................................
................................................................................... 1.0 mm (0.039 inch)
Ring To Ring Groove Clearance
No. 1 Ring
Standard
................................................................................................................................................... 0.03 -
0.07 mm (0.0012 - 0.0028 inch) Limit ..................................................................................................
................................................................................... 0.1 mm (0.004 inch)
No. 2 Ring
Standard
................................................................................................................................................. 0.02 -
0.06 mm (0.0008 - 0.0024 inch) Limit ..................................................................................................
................................................................................... 0.1 mm (0.004 inch)
Oil Ring
Standard
................................................................................................................................................ 0.10 -
0.35 mm (0.0039 - 0.0138 inch) Limit ..................................................................................................
................................................................................... 1.0 mm (0.039 inch)
Page 941
transfer case.
transfer case.

transfer case.

Page 2921
pushed.

malfunction.
Page 2041

Cooling System - Water Pump Leak Inspection
Water Pump: Technical Service Bulletins Cooling System - Water Pump Leak Inspection
No: TSB-10-14-001
DATE: March, 2010
MODEL: All models
SUBJECT: WATER PUMP LEAK INSPECTION CRITERIA
PURPOSE
This TSB provides inspection criteria for determining a leaking water pump. Following this
procedure will prevent unnecessary replacement.
When examining a vehicle for coolant loss, a complete cooling system diagnosis is required. The
presence of dried coolant residue is not an indication of a defective water pump. Water pump
clearances vary with engine temperature and new water pumps can leak coolant due to the
presence of manufacturing residue (e.g. casting sand), which is flushed from the pump over time.
Because of these and other factors, some evidence of coolant residue near the drain hole is
normal.
AFFECTED VEHICLES All models and years
PROCEDURE
NOTE:
On some models, the vehicle must be raised on a lift to view the underside of the water pump and
its surrounding area.
Some models require the removal of the timing belt cover to inspect the water pump. Refer to the
service manual for details.
INSPECTION
1. The engine should be at normal operating temperature.
2. Inspect the underside of the water pump and the surrounding area.
a. If there is no coolant residue, the water pump is not leaking and should not be replaced.
b. If dry coolant residue is seen, clean the area to prevent confusion during future inspections.
Component Check
Canister Purge Solenoid: Testing and Inspection Component Check
Federal
NOTE: When disconnecting the vacuum hose, make an identification mark on it so that it can be
reconnected to the original position.
1. Disconnect the vacuum hose from the solenoid valve. 2. Disconnect the harness connectors.
3. Connect a hand vacuum pump to nipple (A) of the solenoid valve.
4. Apply a vacuum and check for air-tightness when voltage applied directly to the evaporative
emission purge solenoid and when the voltage is
discontinued.
California
1. Disconnect the vacuum hose from the solenoid valve. 2. Disconnect the harness connectors.
3. Connect a hand vacuum pump to nipple (A) of the solenoid valve.

Page 7019
Marker Lamp: Description and Operation
Page 4048
1. Identify the oil cooler inlet and outlet hoses at the transmission. Mark the hoses with tape or
parts tags for reassembly. Disconnect the oil cooler lines at the transmission. The following
illustrations show the locations of the inlet and outlet hoses for each type of automatic
transmission.
IMPORTANT
Follow the manufacturer's safety precautions described on the aerosol can.
2. Insert the nozzle of the aerosol can to the inlet ("to cooler") hose and secure it with a hose
clamp. Position the other hose so it drains into a waste container.
3. Hold the can upright. Remove the protective flip cap at the top and press firmly on the button to
release the solution.
Specifications
Operating Pressure

Locations
Air Injection Vacuum Control Solenoid Valve: Locations

Page 5472
Page 5566
Suspension Strut / Shock Absorber: Description and Operation
Type: Hydraulic, cylindrical, double-acting type with low-pressure nitrogen gas.
Standard equipment: Vehicles without remote-controlled variable shock absorbers.
Optional equipment: Vehicles with remote-controlled variable shock absorbers.

Page 417

Page 6340
1997 Montero Service Manual, Volume 2, Page 46 Correct the description for D-35 as shown:
Service and Repair
Seals and Gaskets: Service and Repair

REPLACEMENT
1. Release coupling between parking brake cable and the backing plate. 2. Before disconnecting
the brake pipe, drain the brake fluid from the bleeder screw. 3. Remove the nuts securing the
backing plate to the axle housing.
4. Pull the rear axle shaft from axle housing. If the rear axle shaft is hard to remove, use the special
tools.
5. Use special tools with hook attached to remove the oil seal. 6. Apply multipurpose grease to the
oil seal fitting area of the rear axle housing.
7. Drive the new oil seal into the rear axle housing end by using the special tool. 8. Apply
multipurpose grease to the oil seal lip. 9. Install the rear axle shaft.
10. Install the brake tube and perform air bleeding of the brake system from the air bleeder. 11.
Install the parking brake cable and adjust the parking brake lever stroke.
Page 2824
Wire Color Codes
the marking color.

Locations
Turn Signal Flasher: Locations

Page 925
INSPECTION
Page 366
SENSOR VIEW

Page 3993
INSPECTION
Standard value:
Page 5571
Suspension Strut / Shock Absorber: Service and Repair Rear Suspension
REMOVAL
INSTALLATION

Page 5334
a. Oil seal installation (27).
b. O-Rings installation (9, 11, 15 & 23).
Apply specified automatic transmission fluid to the O-rings and install them.
c. Spring installation (16).
Fit the spring to the oil pump body with the larger-diameter end at the terminal assembly side.
d. Side plate installation (8).
Line up the dowel pin hole of the side plate with the dowel pin of the pump body when installing the
side plate.
Page 2307
Page 2289
OPERATION
control module.
rotation.
Page 4361
Page 1031
Drive Belt: Specifications A/C
DEFLECTION (REFERENCE VALUE)
When checked .....................................................................................................................................

............................. 6.5 - 7.5 mm (0.26 - 0.30 inch) When new belt is installed
................................................................................................................................................ 5.0 -
6.0 mm (0.20 - 0.24 inch) When used belt is installed
............................................................................................................................................... 6.5 - 7.5
mm (0.26 - 0.30 inch)
Map Light: Diagram Information and Instructions
Page 2839
on actual vehicles.
Wire Color Codes
Page 2689
retry.
ECU check error
Attachment A


Output Voltage
Voltage 0.6 - 1.0 V


Page 5392
Lubrication and sealing points.
a. Y-Packing/oil seal installation (2 & 3).
1. Install the Y-packing facing the direction shown in the illustration. 2. Use the special tool to
press-fit the oil seal to the gearbox housing so that it faces in the direction shown in the illustration.
b. Oil seal installation (4).
Apply specified automatic transmission fluid to the outside of the oil seal, and then use the special
tools to press the oil seal into the valve housing. Specified fluid: Automatic transmission fluid
"DEXRON II"
Page 57

Specifications
Shift Fork: Specifications
H-L Shift Rail Plug ...............................................................................................................................

.......................................... 32 Nm (24 ft. lbs.)
Page 4569

Alignment Charts
Alignment: Specifications Alignment Charts
Front Wheel Alignment Specifications
TOE-IN
Wheel): 0° to 0° 17' Toe-Out Angle On Turn (Inner Wheel When Outer Wheel Is At 20°): 21° 56'
CAMBER .............................................................................................................................................
................................. (0° 40' ± 30') -1° 10' to -0° 10'
CASTER ..............................................................................................................................................
............................... (3° 00' ± 1° 00') 4° 00' to 2° 00'
KINGPIN INCLINATION ......................................................................................................................

................................................................. 14° 52'
SIDE SLIP: (0 ± 3 mm (0 ± .12 inch)) -3 mm to +3 mm (-.12 to +.12 inch)
STEERING ANGLE
Inner Wheel .........................................................................................................................................

................................................... 29° 40' to 32° 40' Outer Wheel ........................................................
.................................................................................................................................................... 29°
45'
Rear Wheel Alignment Specifications
Toe-In ..................................................................................................................................................
............................ 0 mm (0 inch) (Non-adjustable)
Camber ................................................................................................................................................
.............................................. 0° (Non-adjustable)
Page 3174
OPERATION
Page 4742
SENSOR VIEW
G Sensor O
Page 4852
shown.
Locations
Coolant Temperature Sensor / Switch HVAC: Locations

Page 2288
Page 249
Grounding Markings

Backup Lamp: Diagram Information and Instructions
Locations

Page 6572
Fuel Gauge Sender: Testing and Inspection
To check, remove fuel gauge unit from fuel tank.
1. Check that resistance value between the fuel gauge terminal and ground terminal is at standard
value when fuel gauge unit float is at point F
(highest) and point E (lowest). Standard value:
Point F:.................................................................................................................................................
..................................................3 ± 2 Ohms Point E:...........................................................................
...................................................................................................................110 ± 7 Ohms
2. Check that resistance value changes smoothly when float moves slowly between point F
(highest) and point E (lowest).
Fuel Gauge Unit Float Height
Move float and measure the height A at point F (highest) and B point E (lowest) with float arm
touching stopper.
Standard value:
A:..........................................................................................................................................................
..........................................119.3 mm (4.69 in.) B:................................................................................
..................................................................................................................255.0 mm (10.03 in.)
Page 3438

Page 1284
NOTE (1)
Page 1229
Page 6800

Page 3742
NOTE:
NOTE:
Page 709
OPERATION
Page 1418
^ If all the lash adjusters are found to be normal after the simple lash adjuster check (all rocker
arms are hard to push down), check for other causes for the abnormal noise.
NOTE
CAUTION
bleeding procedures, refer to the air bleeding procedures elsewhere in this bulletin or in the proper
7. Start the engine and make sure the abnormal noise is gone. Make sure to do the air bleeding
operation.
8. On DOHC engines, replace the lash adjusters using the following procedures.
CAUTION
Before removing the lash adjuster, turn the crankshaft to lower the piston of the cylinder being
checked. Otherwise the valve will contact the piston when the valve is pushed down for checking.
In addition, the lash adjuster cannot be removed at the rocker arm lifted by the cam. In this case,
turn the crankshaft so the rocker arm in question is not being lifted by the cam.
a. Use the special tool shown in the service manual to push down the valve and remove the roller
rocker arm.
b. Pull out the lash adjuster from the cylinder head.
c. Bleed the air from the new adjuster and install it into the cylinder head.
d. Using the special tool, push down the valve and install the roller rocker arm.
NOTE
To install the roller rocker arm, place the pivot end of the rocker arm on the lash adjuster first.
Then, push down the valve and place the slipper end of the rocker arm on the valve stem end.
Simple Lash Adjuster Check
1. Stop the engine.
3. Set the piston of the No. 1 cylinder at top dead center on the compression stroke.
Application and ID
GENERAL INFORMATION

Page 6859
Page 5437
1996 & 1997 Montero Service Manuals, Volume 1, page 37A-19
Specifications
20° C (68° F) Approx. 1,200 Ohm
40° C (104° F) Approx. 500 Ohm

Page 3377
Page 760
Page 1524
Oil Pan: Service and Repair Lower

Federal
REPLACEMENT
1. Remove the under skid plate, undercover. 2. Remove the front exhaust pipe. 3. Drain the engine
oil. 4. Remove the lower oil pan bolts.
5. Place a wooden block to the oil pan, lower as shown in the figure and remove by tapping with a
hammer.
CAUTION: The use of an oil pan remover tool No. MD998727, or equivalent, can damage the
upper aluminum made oil pan.
6. Remove sealant from oil pan and cylinder block mating surfaces. Degrease the sealant coated
surface and the engine mating surface.
Page 440

Page 2587
Idle Speed/Throttle Actuator - Electronic: Locations
Component View
Idle Air Control Motor A

A/C - Musty/Moldy Odors In Passenger Compartment
Evaporator Core: All Technical Service Bulletins A/C - Musty/Moldy Odors In Passenger
Compartment
No.: TSB-02-55-005 DATE: July, 2002 MODEL: All with A/C
SUBJECT: MUSTY ODORS FROM AIR CONDITIONING (A/C EVAPORATOR COIL

TREATMENT)
PURPOSE
This bulletin contains instructions for applying Mitsubishi Cooling Coil Coating to help eliminate
musty odors emanating from the air conditioner evaporator coils.
Symptom/Condition
The customer may complain of an unpleasant, "musty" odor in the passenger compartment when
the fan blower is switched on. This condition can be related to the area where the vehicle is
operated, occurring more often in humid climates.
Cause
The unpleasant "musty" odor from the air conditioner system occurs when condensation, which is a
normal occurrence, forms in and around the air conditioner's evaporator coil and mixes with
airborne pollutants and substances.
Remedy
To eliminate these odors, treat the air conditioner evaporator/cooling coil with Mitsubishi Cooling
Coil Coating. This coating will not only eliminate the odors, but will protect the evaporator coil.
On most vehicles, the coating can be applied onto the A/C evaporator coil surfaces through the
interior air recirculate door. This door is usually accessible from behind the glove box.
AFFECTED VEHICLES
All Mitsubishi vehicles equipped with air conditioning
PROCEDURES
IMPORTANT
Follow these procedures exactly. If you do not allow enough time for drying and curing, the coating
will wash away with the condensate, causing a comeback.
The complete treatment takes about 2 hours including drying and curing. Actual labor, however, is
about 20 minutes.
CAUTION
Safety Precautions to follow when using Mitsubishi Cooling Coil Coating
^ Keep out of reach of children.
^ Avoid contact with skin and eyes.
^ Wear skin and eye protection.
^ Avoid breathing vapors. Use a breathing protection mask (3M: 07185 is recommended).
If skin or eye contact occurs, wash skin or flush eyes with generous amounts of water.
1. Check the evaporator for airflow clogging or blockage by leaves or other foreign materials and
remove the blockage before proceeding.
NOTE:
If the buildup of the materials causing the clogging or blockage is excessive, replace the evaporator
assembly
Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions
Page 1957
Page 2114
on actual vehicles.
Wire Color Codes
Page 4551
B. Snap ring installation. (1)
1. Select a snap ring that will adjust the end play of the rear output shaft ball bearing to the
standard value.

Idle Speed/Throttle Actuator - Electronic: Component Tests and General Diagnostics
Hint 1: If the number of stepper motor steps increases to 100-120 steps or decreases to0 step, the
cause is probably a malfunction of the stepper motor or damaged or disconnected wiring of the
harness. Hint 2: If the number of stepper motor steps is outside the standard value even through
the results of the checking of the harness of the idle air control motor and of the component itself
indicate no abnormal condition, the cause is probably one of the following. (1) Incorrect adjustment
of the standard idling speed. (2) Deposits adhering to the throttle valve. (3) Air drawn into the intake
manifold from a leaking gasket, etc. (4) Incomplete combustion inside a cylinder (Malfunction of
spark plugs, ignition coil, injectors, compression pressure, etc.)
INSPECTION
Using Scan Tool
NOTE: When the vehicle is new [driven approximately 500 km (300 miles) or less] the number of
steps may be about 30 steps greater than the standard value indicated above.
CAUTION: When the select lever is shifted to the D position, the brakes must be used to prevent
the vehicle from moving forward.
HARNESS INSPECTION
STEP 1. Check for continuity between the idle air control motor and the MFI relay. -
Idle air control motor connector: Disconnected
- MFI relay connector: Disconnected
NOTE: -
OK: GO TO STEP 2 NG: Repair the harnesses. (A2 - B1, A5 - B1).

Page 1348
Overdrive Planetary Gear and Overdrive Direct Clutch
Page 5449
Ball Joint: Testing and Inspection Lower
END PLAY INSPECTION
Check the lower ball joint end play by the following procedure. 1. Use a dial indicator to measure
the lower ball joint end play.
Limit: 0.3 mm (.012 inch)
2. If the lower ball joint end play exceeds the service limit, replace the lower ball joint.
Page 6489

Page 4775
Page 3830
Limit: 1.84 mm (0.0724 inch)
the limit.
NOTE: -
Page 481
HARNESS INSPECTION
NOTE: -
- 92)
control module. -
(A3 - 90, A7 - 19)

Page 3900
Output Shaft: Service and Repair
DISASSEMBLY

Page 1496
Engine Oil: Service Precautions
WARNING:
PROLONGED AND REPEATED CONTACT WITH MINERAL OIL WILL RESULT IN THE
REMOVAL OF NATURAL FATS FROM THE SKIN, LEADING TO DRYNESS, IRRITATION AND
DERMATITIS. IN ADDITION, USED ENGINE OIL CONTAINS POTENTIALLY HARMFUL
CONTAMINANTS WHICH MAY CAUSE SKIN CANCER. ADEQUATE MEANS OF SKIN
PROTECTION AND WASHING FACILITIES MUST BE PROVIDED.
RECOMMENDED PRECAUTIONS
- The most effective precaution is to adapt working practices which prevent, as far as practicable,
the risk of skin contact with mineral oils. For example; Use enclosed systems for handling used
engine oil and degrease components, where practicable, before handling them.
- Avoid prolonged and repeated contact with oils, particularly used engine oils.
- Wear protective clothing, including impervious gloves where practicable.
- Avoid contaminating clothes, particularly underpants, with oil.
- Do not put oily rags in pockets, the use of overalls without pockets will avoid this.
- Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned
regularly and kept separate from personal clothing.
- Where there is a risk of eye contact, eye protection should be worn. For example; chemical
goggles or face shields. In addition, an eye wash facility should be provided.
- Obtain First Aid treatment immediately for open cuts and wounds.
- Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin
cleansers and nail brushes will help). After cleaning, the application of preparations containing
lanolin to replace the natural skin oils is advised.
- Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin.
- Use barrier creams, applying them before each work period, to help the removal of oil from the
skin after work.
- If skin disorders develop, obtain medical advice immediately.

Page 5585
BEARING REPLACEMENT
Page 6689


Page 6871
Wire Color Codes
the marking color.

Page 4267
Wire Color Codes
the marking color.

Page 169
Wire Color Codes
the marking color.

Specifications
Ash Tray Lamp: Specifications
Ashtray illumination light ......................................................................................................................
............................................................... 1.4 (74) W

Page 4069
Wire Color Codes
the marking color.

Ignition Cable: Testing and Inspection
Spark Plug Cable

Page 3353

Front Speaker (LH)
Speaker: Service and Repair Front Speaker (LH)
Front Speaker LH - Removal And Installation
Removal
Installation

Seat Belt Reminder Buzzer: Diagram Information and Instructions
Page 3302
Idle Speed/Throttle Actuator - Electronic: Description and Operation
OPERATION
- The amount of air taken in during idling is regulated by the opening and closing of the servo valve
located in the air passage that bypasses the throttle valve.
- The servo valve is opened or closed by the activation of the stepper motor (incorporated within
the idle air control motor in the forward or reverse direction.
- Battery positive voltage is supplied, by way of the MFI relay, to the coil of the stepper motor. The
engine control module switches ON the power transistors (located within the engine control
module) in sequential order, and, when current flows to the stepper motor coil, the stepper motor is
activated in the forward or reverse direction.
Page 3577
OPERATION
ground.
Page 3827
Page 5702
>D< AIR SELECTION CONTROL WIRE (BLOWER CASE SIDE) INSTALLATION
Connect the air selection control wire to the air selection damper lever by following the steps below.
1. Move the air selection control lever to the recirculation position. 2. With the air selection damper
lever pressed inward in the direction indicated by the arrow, connect the inner cable of the air
selection lever and
then use a clip to secure the outer cable.

Specifications
Sensor Bolt
Torque 7 ft.lb
Specifications
Output Shaft: Specifications
End Play:
Input Gear Bearing

............................................................................................................................................................
0-0.06 mm (0-0.0024 inch) Rear Output Shaft Bearing
................................................................................................................................................ 0-0.08
mm (0-0.0031 inch) Rear Output Shaft Lock Nut
.........................................................................................................................................................
113 Nm (83 ft. lbs.)
Page 3501

Ignition Coil: Diagram Information and Instructions
Page 5413
Steering Wheel: Testing and Inspection Checking Return to Center
To check the return of the steering wheel to the center, carry out a road test and check the
following points. 1. Make gentle and sharp turns and check that there is no appreciable difference
in steering effort and return to center between right and left turns. 2. Drive at a speed of about 35
km/h (22 mph), turn the steering wheel 90° clockwise or counterclockwise, and release the wheel a
second or two
later. If the wheel returns more than 70°, the return may be considered good.
NOTE: When the steering wheel is turned abruptly, momentary hard steering might result, but this
does not mean a problem. It is caused by low oil pump delivery during idling.
Page 5603
Tires: Technical Service Bulletins Tires - Goodyear(R) Product Service Locations
SUBJECT: GOODYEAR TIRE PRODUCT SERVICE LOCATIONS
PURPOSE
In the event of any issue related to Goodyear tires, customers should first contact Goodyear Tire
Company Customer Service at 1-800-321-2136.
If Goodyear Customer Service cannot resolve the customer's Concern, the nearest Goodyear
North American Product Service Field Manager as shown may be contacted.
AFFECTED VEHICLES Lancer, Diamante, Eclipse, Eclipse Spyder, and Galant models equipped
with Goodyear tires.
Page 7109
Turn Signal Lamp: Testing and Inspection Turn-Signal Light and Lighting Switch Check
Lighting Switch
1. Remove the column cover lower. 2. Remove the column cover upper. 3. Turn the screws
indicated by arrows in the illustration, and then remove the switch. 4. Operate the switch and check
for continuity between the terminals.
Upper
Oil Pan: Service and Repair Upper
REPLACEMENT
1. Remove the lower oil pan. 2. Remove the front differential carrier. 3. Refer to the illustration for
the service procedures, noting the following:
4. Install a bolt with a diameter x length of 10 x 38 mm (0.39 x 1.50 inch) to link the upper oil pan
with the transmission in the hole of the upper oil
pan, as shown, and then tighten the bolt to remove the upper oil pan.
5. Remove the sealant from the oil pan and cylinder block mating surfaces. 6. Degrease the
sealant coated surface and the engine mating surface.
Page 5869
1997 Montero Service Manual, Volume 1, Page 52B-14 Add the new SRS troubleshooting
Maintenance Required Lamp/Indicator: Diagram Information and Instructions
Front
Brake Pad: Testing and Inspection Front
NOTE: The brake pads have indicators that contact the brake disc when the brake pad thickness
becomes 2 mm (0.079 inch), and emit a squealing sound to warn the driver. Always replace the
pads on both sides, and also the brake pads for the wheels on the opposite side at the same time.
If there is a significant difference in the thicknesses of the pads on the left and right sides, check
the sliding condition of the piston, lock pin and guide pin.
- Check the brake pad thickness through the caliper body check port. The standard value is 10 mm
(0.39 inch) and the limit is 2.0 mm (0.079 inch).
CAUTION: Do not wipe the special grease from the lock pin. Do not contaminate the lock pin.
Page 4286
Axle Shaft: Overhaul
DISASSEMBLY
A. Bearing removal. (2)
1. Bend the outside periphery of dust cover inward with a hammer.
2. After the special tool has been installed as shown, tighten the nut of the special tool until section
"A" of the special tool touches the bearing
outer race.
3. Press out the inner shaft from the bearing.
CAUTION: Do not allow the inner shaft to drop.
ASSEMBLY

Page 5951
Grounding Markings

Page 443


Page 5564
Suspension Strut / Shock Absorber: Electrical Diagrams
Remote Controlled Variable Shock Absorber System (Part 1 Of 2)

Page 3352
Grounding Markings

Page 3853
B. Second brake piston removal. (7)
1. With the second brake piston held, blow air into the second brake drum through the oil hole to
remove the second brake piston.
remove.
INSPECTION
ASSEMBLY
One-Way Clutch, A/T

Page 8
1992-95 Montero Service Manual, Volume 2, Page 54-144 Delete the marked-through information
from the manual as shown and replace it with the new procedures.
Page 2972


Page 4722
Page 4568

Page 4061
Component View
Page 280

NOTE: -
(A1 - Ground)
(A2 - 88)
With Scan Tool
connector.
Page 4544
Page 3010
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A1 - 92)
control module. -
Component Locations

Page 5300
INSPECTION
Component Check
looseness.
Service and Repair
Ignition Switch Lock Cylinder: Service and Repair
Ignition Switch - Removal And Installation
Removal
To remove follow the steps listed in the image and note the following.
Step 6: Steering Lock Cylinder Removal
1. Insert the ignition key into the steering lock cylinder and place the key in the ACC position. 2.
Press the lock pin down with a small Phillips screwdriver to remove the steering lock cylinder.
Installation

Page 1743
Fan Blade: Testing and Inspection
- Check the blades for damage and cracks.
- Check for cracks or damage around the bolt holes in the fan hub.
- If any portion of fan is damaged or cracked, replace cooling fan.

Idle Speed/Throttle Actuator - Electronic: Component Tests and General Diagnostics
Hint 1: If the number of stepper motor steps increases to 100-120 steps or decreases to0 step, the
cause is probably a malfunction of the stepper motor or damaged or disconnected wiring of the
harness. Hint 2: If the number of stepper motor steps is outside the standard value even through
the results of the checking of the harness of the idle air control motor and of the component itself
indicate no abnormal condition, the cause is probably one of the following. (1) Incorrect adjustment
of the standard idling speed. (2) Deposits adhering to the throttle valve. (3) Air drawn into the intake
manifold from a leaking gasket, etc. (4) Incomplete combustion inside a cylinder (Malfunction of
spark plugs, ignition coil, injectors, compression pressure, etc.)
INSPECTION
Using Scan Tool
NOTE: When the vehicle is new [driven approximately 500 km (300 miles) or less] the number of
steps may be about 30 steps greater than the standard value indicated above.
CAUTION: When the select lever is shifted to the D position, the brakes must be used to prevent
the vehicle from moving forward.
HARNESS INSPECTION
STEP 1. Check for continuity between the idle air control motor and the MFI relay. -
Idle air control motor connector: Disconnected
NOTE: -
OK: GO TO STEP 2 NG: Repair the harnesses. (A2 - B1, A5 - B1).

Page 4872
DISASSEMBLY AND ASSEMBLY
1. Remove the lock pin and guide pin. 2. Remove the bushing and caliper support (pad, clip and
shim.) 3. Remove the pin boot, boot ring and piston boot. 4. Pump in compressed air through the
brake hose installation hole and remove the pistons and piston boot.
Locations

Front Suspension
Alignment: Service and Repair Front Suspension
Toe-In
1. Measure the toe-in.
Standard value:
Wheel): 0° to 0° 17'
2. If the toe-in is not within the standard value, adjust the toe-in by turning the left and right tie rod
turnbuckles by the same amount (in opposite
directions).
CAUTION: The difference between the left and right tie rods should not exceed 5 mm (.2 inch).
3. After adjusting, use a turning radius gage to confirm that the steering wheel turning angle is
within the standard value range.
Toe-Out Angle on Turns
To check the steering linkage, especially after the vehicle has been involved in an accident or if an
accident is presumed, it is advisable to check the tow-out angle on turns in addition to the wheel
alignment. Conduct this test on the left turn as well as on the right turn.
Standard value: 21° 56' (inner wheel when outer wheel at 20°)
Camber
Standard value: (0° 40' ± 30') -1° 10' to -0° 10' (Left/right deviation within 30') 1. Adjust the camber
by increasing or decreasing the thickness of the adjusting shim provided between the upper arm
shaft and the crossmember.
NOTE: -
Standard thickness of the shim is 4 mm (.16 inch).
- The number of shims is three or less.
Camber adjustment shim (yellow plating):
Part number Thickness
MB176288 1.0 mm (.039 inch)
MB176289 2.0 mm (.079 inch)
Caster
Standard value: (3° 00' ± 1° 00') 4° 00' to 2° 00' (Left/right deviation within 30')
1. Caster is preset at the factory and cannot be adjusted. 2. If caster is not within the standard
value, replace bent or damaged parts.
Page 66
RELAY VIEW

Page 4808

Page 3332

Page 2008
OPERATION
module.
Page 5149
Wire Color Codes
the marking color.

Locations

Page 2222

control module.
Page 6252
CONTROL UNIT VIEW
Page 7183
4. Insert the leaded end of the lowering wire into the wire hole on the bottom surface of the drum.
Make sure that the wire is wound on the first groove of the drum without any looseness from the
underside of the drum.
5. Wind the lifting wire onto the drum.
a. Insert the top end of the lifting wire in the wire hole on the top surface of the drum.
b. Raise the forward part of the drum to its upright position and put the lifting wire into the last
groove in the drum.
c. Place the drum in its original position making sure to hold the drum so the wire does not come
off.
Note:
For assembling the power window motor and regulator after the drum and wire assembly is
complete, refer to the POWER WINDOW MOTOR AND REGULATOR ASSEMBLY section at the
beginning of this bulletin.
6. Cut off the wires that have been used to compress the spring.
PARTS INFORMATION
Page 5864
1993-96 Mirage Service Manual, Volume 1, Page 52B-3O Add the new SRS troubleshooting

Resistance/Torque

Page 6923
Dome Lamp: Description and Operation
- Battery positive voltage is constantly applied to the dome light and cargo space light.
- When the dome light switch or the cargo space light switch is set to the ON position, the dome
light or cargo space light always illuminates. When the switch is set to the DOOR position, the
dome light or cargo room light illuminates when any door is opened.
Voltage Regulator: Testing and Inspection
Regulated Voltage Test
Voltage Regulation Table
This test determines if the voltage regulator is correctly controlling the generator output voltage.
1. Be sure to check the following:
- Generator installation and wiring connections.
- Battery fully charged. See: Battery/Description and Operation
- Generator drive belt tension.
- Fusible link.
- Abnormal noise from the generator while the engine is running

2. Turn the ignition switch to the OFF position. 3. Disconnect the negative battery cable. 4. Connect
a digital-type voltmeter between the generator "S" terminal and the ground. (Connect the (+) lead of
the voltmeter to the "S" terminal.
Connect the (-) lead of the voltmeter to a secure ground or to the battery (-) terminal.)
5. Disconnect the generator output wire from the generator "B" terminal. 6. Connect a DC test
ammeter with a range of 0 - 100 A in series between the "B" terminal and the disconnected output
wire. (Connect the (+) lead
of the ammeter to the "B" terminal. Connect the (-) lead of the ammeter to the disconnected output
wire.)
7. Reconnect the negative battery cable. 8. Connect a tachometer or scantool. 9. Turn the ignition
switch to the ON position and check that the reading on the voltmeter is equal to the battery
voltage.
NOTE: If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between
the generator "S" terminal and the battery (+) terminal.
10. Check to be sure all lights and accessories are OFF. 11. Start the engine. 12. Increase the
engine speed to Approx. 2,500 rpm. 13. Read the voltmeter when the current output by the
generator becomes 10 A or less. 14. If the voltage reading conforms to the value in the voltage
regulation table the voltage regulator is operating normally.
If the voltage is outside the standard value, there is a malfunction of the voltage regulator or of the
generator.
15. After the test, lower the engine speed to the idle speed.
Specifications
Timing Belt: Specifications
1997 CA vehicles, replacement at 60,000 mile intervals is recommended but not required. On all
1997 models, replace every 100,000 miles (if not previously replaced). On 1998 & later CA, CT, MA
vehicles replacement at 60,000 mile intervals is recommended but not required. On all 1998 & later
models replace every 100,000 miles (if not previously replaced).

Page 2602
Idle Speed/Throttle Actuator - Electronic: Oscilloscope Patterns and Waveforms
(1) Disconnect the stepper motor connector, and connect the special tool (test harness:
MB998463) in between. (2) Connect the analyzer special patterns pickup to the stepper motor-side
connector terminal (1) (red clip on the special tool), terminal (3) (green
clip), terminal (4) (black clip) and terminal (6) (yellow clip) respectively.
Connect the analyzer special patterns pickup to ECM terminals (4), (5), (17) and (18).
Standard wave pattern Observation conditions
The wave pattern appears for an instant, but soon disappears.
Check that the standard wave pattern appears when the stepper motor is operating.
Point A: Presence or absence of induced voltage from the motor turning. (Refer to the abnormal
wave pattern.)
Point B: Height of coil back electromotive force.

Page 6929
RELAY VIEW
Turn Signal And Hazard Flasher Unit H

Locations

Page 2531
check mark button.
VCI COMPONENTS
Page 7092
Page 2767
Page 6459

Page 6051


Page 1820

Page 447
Page 5425
Tie Rod End: Testing and Inspection Breakaway Torque Check
1. Use the special tool to disconnect the tie rod from the knuckle.
CAUTION: -
Use cord to bind the special tool closely so it won't become separated.
- Loosen the nut but do not remove it.
2. Move ball joint stud several times and install nut on stud.
Measure ball joint breakaway torque with special tools. Standard value: 1 - 3 Nm (9 - 26 inch lbs.)
3. When the measured value exceeds the standard value, replace the tie rod end. 4. When the

Page 5908
6. Turn the ignition key to the "LOCK' position, disconnect the negative battery cable and tape the
terminal.
work.
Step 7: Clock Spring Installation
The content of this article reflects the changes identified in TSB-08-52B-001
A modified clock spring has been adopted for Service Parts on affected vehicles as of September
2007. New and old style parts are interchangeable. This TSB advises the procedures for alignment
of the neutral point of the new clock spring when a part is replaced.
Parts Identification
Replacement Clockspring Alignment As Per Manual Update TSB-08-52B-001
Mating Mark Alignment
Replacement Clockspring Alignment As Per Manual Update TSB-08-52B-001 (Part 2)
1. Turn the clockspring clockwise fully. 2. Turn the clockspring anti-clockwise (counter-clockwise)
approx. 3/4 turns to align the mating marks. 3. Check that the white or yellow roller can be seen
from the window for checking the neutral point when the mating marks are aligned.
Page 2985

Specifications
.................................................................... 1.12 W
Page 5662
Blower Motor Relay: Testing and Inspection
1. Remove the heater relay from the junction box. 2. Use an ohmmeter to check for continuity
between the terminals.
Page 2129
Oxygen Sensor: Locations Left Bank Heated Oxygen Sensor (Front & Rear)

Page 4435
Page 5604
Tires: Technical Service Bulletins Snow Tire - Recommendations
NO.: TSB-97-31-001 DATE: January, 1997 MODEL: All 1997 Models
SUBECT: SNOW TIRE RECOMMENDATIONS
PURPOSE Snow tires are available for most 1997 models. This bulletin lists recommended
Michelin and Yokohama snow tires for these vehicles.
Snow tires are not available from Michelin and Yokohama for the following models:
1997 Eclipse GSX 1997 Montero SR 1997 Montero Sport 1997 3000GT SL and VR4
NOTE:
Refer to TSB-97-31-003 REV, issued 12/96, for tire chain recommendations for all 1997 models.
For further snow tire information, contact your local Michelin or Yokohama tire dealer or their
national office at:
Michelin (800) 847-3435 Yokohama (800) 423-5444
AFFECTED VEHICLES
All 1997 models
SERVICE INFORMATION
Refer to the Snow Tire table in this bulletin. Remember that speedometer readings with snow tires
installed sometimes vary slightly from speedometer readings with standard tires.
When snow tires are used, they must be installed on all four wheels. Do not mix and match tire
types.
Page 1863
Thermostat: Service and Repair
REPLACEMENT
1. Drain the engine coolant. 2. Refer to the illustration for the service procedures, noting the
following:
- Install the thermostat so that the jiggle valve is facing straight up.
NOTE: -
Make absolutely sure that no oil is adhering to the rubber ring of the thermostat.
- In addition, be careful not to fold over or scratch the rubber ring when inserting.
Page 105

Page 2210
Component View
Specifications
Cigarette Lighter: Specifications
Max. Input ............................................................................................................................................
....................................................................... 120 W Reset time ........................................................
........................................................................................................................................... Within 18
second Thermal fuse fusion temperature
..................................................................................................................................... 180 °C - 250
°C (356 °F - 482 °F)
Page 6460


Page 5187
Noise Suppressor Mounting Location
Component View
Noise Capacitor B
Page 2515
Voltage Meter Check
Volt Meter Gauge: Testing and Inspection Voltage Meter Check
Voltage Meter Check
Use an ohmmeter to measure the resistance between the terminals.
Standard value : 380 - 460 Ohms

Page 4171
F. Drive pinion assembly removal. (18)
1. Make mating marks on the drive pinion and companion flange.
CAUTION: The mating mark made on the companion flange must not be on the coupling surface of
the flange yoke and the front propeller shaft.
2. Drive out the drive pinion together with the drive pinion spacer and the drive pinion shims.
G. Drive pinion front bearing inner race removal. (22)
Use the special tools to pull out the front bearing inner race.
H. Drive pinion rear bearing outer race/drive pinion front bearing outer race removal. (27 & 28)
1. Use the brass rod to drive out the drive pinion rear bearing outer race from the gear carrier. 2.
Drive out the front bearing outer race in the same manner.
Inspection
1. Check the companion flange for wear or damage. 2. Check the oil seal for wear or deterioration.
3. Check the bearings for wear or discoloration. 4. Check the gear carrier for cracks. 5. Check the
drive pinion and drive gear for wear or cracks. 6. Check the side gears, pinion gears and pinion
shaft for wear or damage. 7. Check the side gear spline for wear or damage.
Page 1611
Grounding Markings

INSPECTION
Locations
Number One Cylinder
California
Oxygen Sensor: Testing and Inspection California
HARNESS INSPECTION
STEP 1. Check for continuity between heated oxygen sensor and MFI relay. -
NOTE: Insert the probes of the circuit tester into both ends of the harness.
OK: GO TO STEP 2 NG: Repair the harness. (A, B, C, D1 - E3)

Procedures
Air Bag: Procedures
Before either disposing of a vehicle equipped with an air bag, or prior to disposing of the air bag
module, be sure to first follow the procedures described below to deploy the air bag(s).
UNDEPLOYED AIR BAG MODULE DISPOSAL
CAUTION:
1. If the vehicle is to be scrapped, or otherwise disposed of, deploy the air bag inside the vehicle. If
the vehicle will continue to be operated and only
the air bag module is to be disposed of, deploy the air bag outside the vehicle.
2. Since a large amount of smoke is produced when the air bag is deployed, select a
well-ventilated site. Moreover, never attempt the test near a
smoke sensor.
3. Since there is a loud noise when the air bag is deployed, avoid residential areas whenever
possible. If anyone is nearby, give warning of the
impending noise.
4. Suitable ear protection should be worn by personnel performing these procedures or by people
in the immediate area.
DEPLOYMENT INSIDE THE VEHICLE (when disposing a vehicle)
1. Open all windows and doors of the vehicle. Move the vehicle to an isolated spot. 2. Disconnect
the negative (-) and positive (+) battery cables from the battery terminals, and then remove the
battery from the vehicle.
CAUTION: Wait at least 60 seconds after disconnecting the battery cables before doing any further
work.
3. Remove the steering column cover lower.
4. Remove the connection between the clock spring 2-pin connector (red) and the dash wiring
harness connector.
NOTE: If the clock spring connector is disconnected from the dash wiring harness, both electrodes
of the clock spring connector will be automatically shorted to prevent unintended deployment of the
air bag due to static electricity, etc.
5. Open the glove compartment. 6. Disconnect the 2-pin (red) connector of the air bag module
(front passenger's side) from the body wiring harness connector.
NOTE: If the air bag module (front passenger's side) connector is disconnected from the body
wiring harness, both electrodes of the air bag module (front passenger's side) connector will be
automatically shorted to prevent unintended deployment of the air bag due to static electricity, etc.
Page 5733
PARTS INFORMATION
Use the genuine Mitsubishi Parts listed.
Page 2768
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Page 968
speed.
Page 6281
II. Paint Manufacturers' Stock Numbers for 1997 Exterior Refinishing.

Page 3373
on actual vehicles.
Wire Color Codes
Page 2079

Torque 1.5 ft.lb

Page 6003
Antenna Motor: Component Tests and General Diagnostics
Antenna Motor Check
Motor Antenna Check
1. Remove the radio with tape player. See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service
and Repair 2. Disconnect the motor antenna control module connector and check that the antenna
goes up when the positive battery terminal is connected to
terminal (1) and the negative battery terminal is connected to terminal (4), and check that it goes
down when the connections are reversed.
Antenna Motor Control Unit Check
Motor Antenna Control Unit Check
Motor Antenna Control Unit Check - Chart
1. Remove the radio with tape player. See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service
and Repair 2. Remove the motor antenna control unit mounting bolt. 3. With the ignition switch
turned to ACC or ON, operate the radio switch and check the voltage between the terminals while
the antenna is being
raised and lowered.

Page 7184
Refer to CAPS or the parts catalog microfiche for power window motor and regulator part numbers.
Standard warranty procedures and policies apply. The Labor Operation Time Schedule (LOTS)
manual has the correct labor operation number and time information for each model covered by
this bulletin. Refer to the LOTS manual when replacing a power window motor an/or regulator on a
vehicle which is still within the warranty period.
Page 1544

Page 747
- Example 2
normal.
Application and ID
GENERAL INFORMATION

Page 5759
Lubricant Differences
Mineral oil is used to lubricate the compressor in an R12 system. Since mineral oil is incompatible
with R134a, it cannot be used in an R134a system. Synthetic oil must be used with R134a. There
are different types, and not all of these are compatible. For instance, SUN PAG 56 must not be
intermixed with ND-OIL8. MMSA Refrigerant Oil A993ZC1X03 may not be mixed with MMSA
Refrigerant Oil A9937C1X04. Consult the under-hood label or the A/C Specifications page of the
vehicle service manual for the correct oil for a particular vehicle.
Retrofitting Systems
Mitsubishi Motor Sales of America, Inc. is monitoring the supply of R12 to arrive at an appropriate
point for offering retrofit kits for its 1993 and earlier models. Retrofit kits will vary from vehicle to
vehicle.
It will be necessary to educate customers about retrofitting. Please assure those who think
retrofitting is mandatory that it is not, and advise them that the decision is fundamentally an
economic one. Whether or not to retrofit depends on the relative costs of R12 and R134a (and
these are changing constantly) and the parts and labor involved in retrofitting the customer's car.
Retrofitting a car to use R134a involves evacuating the car's system, recovering the refrigerant,
flushing the system, installing the components, hoses and fittings that make up the retrofit kit, and
recharging the system with R134a.
Recovery and Recycling of Refrigerants
When servicing an A/C system, the refrigerant that is in the system must be drawn from the system
into a storage container. Before this is done, assure yourself that the system is not contaminated.
Find out the vehicle's service history, if possible. If the vehicle has been to several shops to cure a
mysterious A/C problem, be extremely wary. Inspect the service fittings for signs of tampering.
Makeshift or damaged fittings could indicate tampering and possible contamination. If your shop
has a Refrigerant Identifier, such as the one sold by Snap-On, connect the Refrigerant Identifier to
the system. If it identifies a flammable gas, or a mixture of refrigerants, or a refrigerant other than
what the system was designed for, you may want to refuse to service the system. If the Refrigerant
Identifier shows excessive air, the air can be removed from the refrigerant by using a recycling
machine with a non-condensable purge.
The recovery equipment must have shutoff valves within 12" of the hoses' service ends. With
valves closed, connect the hoses to the vehicle's A/C service fittings. Recover the refrigerant,
continuing until the vehicle's system shows a vacuum instead of pressure. Turn off the
recovery/recycling unit for at least five minutes. If the system still has pressure, repeat the recovery
process to remove any remaining refrigerant. Continue until the A/C system holds a stable vacuum
for two minutes. Then close the service equipment valves and disconnect the hoses. Measure the
recovered oil and replace it with the same amount and type.
Storing Recycled Refrigerant
Use only "DOT CFR Title 49" or "UL Approved" containers for recycled refrigerant. The letters are
stamped into the metal of the ring surrounding the valve. Containers specifically made for R134a
refrigerant should be marked accordingly. Never use disposable containers for storing refrigerant.
Transferring Recycled Refrigerant
Use only DOT-approved containers. Evacuate the container to at least 27" Hg before transferring
the refrigerant. Never fill a container to more than 60% of its gross weight rating. For example, a
30-lb. container would take 18 lb. and a 50-lb. container would take 30 lb.
Recycled refrigerant is used refrigerant that has been recovered from customers vehicle A/C
systems by any shop servicing A/C. This same shop may also send recovered refrigerant to a
reclaimer who processes the refrigerant so that it meets purity standards that are higher than those
for recycled refrigerant. This refrigerant is known as reclaimed refrigerant. When buying reclaimed
refrigerant, be sure it meets API 700-88 requirements. The EPA Hotline (1-800-296-1996) can
provide information on approved refrigerant reclaimers.
Before using any container of recycled refrigerant, check for non-condensable gases (air). This can
be done with the Refrigerant Identifier or by the following process:
1. Keep the container at 65°F for at least 12 hours, out of direct sunlight.
2. Connect a pressure gauge calibrated in 1-psi divisions to the container and read the pressure.
3. With an accurate thermometer, measure the air temperature within 4 in. of the container.
4. Compare the pressure in the chart. See if the pressure is at or below the limit shown.
5. If the pressure of the refrigerant is lower than the limit shown for a given temperature, the
refrigerant is OK to use as is.
Page 1295
3. While gently pushing down the internal steel ball using stiff wire (0.5 mm diameter), move the
plunger through 5 to 10 strokes until it slides smoothly. This will remove dirty oil from the lash
adjuster and loosen the plunger.
! CAUTION
The steel ball spring is extremely weak. If the wire is pushed in with too much force, the lash
adjuster will be damaged.
If the plunger remains stiff or the mechanism appears to be abnormal, replace the lash adjuster.
4. Remove the lash adjuster from container A. Then gently push down the steel ball and push the
! CAUTION
On DOHC engines, point the oil hole toward container A. Do not point the oil hole toward anyone.
5. Place the lash adjuster in container B. Then gently push down the internal steel ball using stiff
wire (0.5 mm diameter). Move the plunger through 5 to 10 strokes until it slides smoothly. This will
clean the lash adjuster's pressure chamber.
Page 872
Page 2744


Page 702

Page 550
Wire Color Codes
the marking color.

Page 6347
1998 Montero Service Manual, Volume 2, Page 90-139 Replace the circuit diagram crossed-out on
the previous page of this bulletin with the new corrected diagram shown.
Page 5955
Wire Color Codes
the marking color.

Page 6650
high pressure side.
pressure side.
Page 2639

Page 3571
Grounding Markings

Locations

Page 6853

Page 5201
Grounding Markings

Page 3979
Page 166

Page 5193
Page 5044
Battery: Testing and Inspection Battery Testing Procedure
Load Test Chart
Load Test Rate Chart
Battery Testing Procedure

Page 6610
Low Fuel Lamp/Indicator: Electrical Diagrams

Fluid - Differential: Capacity Specifications
Front Axle ............................................................................................................................................
...................................................................... 1.22 qts.
Rear Axle .............................................................................................................................................

....................................................................... 3.3 qts.
Page 4661
Grounding Markings

Page 3903
Page 3644
INSPECTION
the ground.
Page 4734
ABS Light: Testing and Inspection
Check that the ABS warning light illuminates as follows.
1. When the ignition key is turned to "ON," the ABS warning light illuminates for approximately 1
second and then switches "OFF." 2. When the ignition key is turned to "START," the ABS warning
light remains illuminated. 3. When the ignition key is released from the "START" position, the ABS
warning light illuminates for approximately 1 second and then stays
switched "OFF."
4. If the illumination is other than the above, check the Diagnostic Trouble Codes (DTC). See:
Testing and Inspection/Initial Inspection and
Diagnostic Overview
Page 3824
Specifications
..................................................................... 1.12 W
Page 4460
Page 4446
on actual vehicles.
Wire Color Codes
Page 1315
procedure.
NOTE
procedure.
adjuster.

Page 6043
Page 4024
Shift Cable: Service and Repair
Specifications
Oil Filter Housing: Specifications
Bracket/Housing Bolts
M8 ........................................................................................................................................................
......................................... 24 Nm (17 ft. lbs.) M10 ..............................................................................
................................................................................................................. 40 Nm (30 ft. lbs.)

Switch Adjustment
V4AW2 A/T.
23A-45
Page 6940
Passing Switch
Passing Switch
Page 4082
INSPECTION
Page 3362
INSPECTION
Page 2960
OPERATION
Page 56
(Part 2 Of 2)
- Measure the voltages between terminal Nos. 12, 25 and 42 (ground terminals) and each
respective terminal.
- The terminal layouts are shown in the illustrations.

Page 4502

Revisions

numbering.

Page 2749
INSPECTION
Using Scan Tool

Page 752

Page 3814
Clutch: Specifications First, Second, and Reverse Brake Clutch
Clearance Between:
Second Brake Drum And Plate

............................................................................................................................ 0.70-1.22 mm
(0.0275-0.0480 inch) Snap Ring And Brake Flange
............................................................................................................................... 0.62-1.98 mm
(0.0244-0.0779 inch)
First & Reverse Brake:
Disc Thickness (Limit)

.............................................................................................................................................................
1.51 mm (0.0594 inch) Return Spring Free Length
............................................................................................................................. Approximately
13.09 mm (0.5154 inch)
Second Brake Assembly:
Return Spring Free Length

............................................................................................................................. Approximately
15.05 mm (0.5925 inch)
Second Brake Piston Stroke

............................................................................................................................................... 1.5-3.0
mm (0.059-0.118 inch)
Page 5003
NOTE:
Page 4707
Correction
PURPOSE
AFFECTED VEHICLES
PROCEDURE
NOTE:
Page 4000
the arrow.

Specifications
Brake Fluid: Specifications
Fluid Specification Conforming to DOT 3 or DOT 4

Page 5863
1997 3000GT Service Manual, Volume 1, Page 52B-16 Add the new SRS troubleshooting
Page 3957

Page 2237
HARNESS INSPECTION
control module. -
- 86)
- Ground)

Page 4500

Page 4871
DOT 4 brake fluid.
Rear
Page 2562
Page 903
Page 4163
9. Press-fit the oil seal firmly by using the special tools.
10. Apply multi-purpose grease to the lip of the oil seal and install it to the drive shaft (L.H.). For the
right side, apply multi-purpose grease to the lip
of the oil seal and install to the housing tube and differential mounting bracket (R.H.).
11. Install the inner shaft and drive shaft (R.H.).
CAUTION: -
Do not damage the lip of the oil seal.
- The circlip attached to the Birfield Joint (B.J.) side spline of the drive shaft should be replaced with
a new clip.
12. Install the actuator and secure the harness with the clamp. 13. Install the shock absorber. 14.
Install the hub and knuckle assembly. 15. Install the under cover.
Replacement
Page 2543
Engine Control Module: Locations

Page 1188
Wire Color Codes
the marking color.

Page 4968

Page 3077
Wire Color Codes
the marking color.

Page 4969
SENSOR VIEW
G Sensor O
Page 2938
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A1 - 92)
control module. -
Specifications
Front Hub:

.......................................................................................................................................... 0.05 mm
................................................................................................................................................. 0.3 -
1.3 Nm (2.6 - 11.3 inch lbs.)

.......................................................................................................................................................... 5
- 8 N (1.1 - 4.0 lbs.)
Page 1887
Exhaust Manifold: Service and Repair

Page 6690
on actual vehicles.
Wire Color Codes
Page 2278
Torque 1.5 ft.lb

Page 4779

Page 6712

Locations
Electronic Noise Suppressor: Locations

Page 6004
Antenna Motor: Service and Repair
Motor Antenna And Antenna Feeder Cable - Removal And Installation
Removal
To remove follow the steps listed in the image and note the following :
Motor Antenna And Antenna Feeder Cable Removal
Step 8: Motor Antenna and Antenna Feeder Cable Removal For ease of installation, tie a cord
which is approximately 3 m (9.84 ft.) in length to the feeder cable. Pull out the feeder cable together
with the antenna base.
Page 3780
OPERATION CHECK
pressure equalizes.

Page 5427
INSPECTION
Component Check
looseness.
Page 2733
Page 6919


Page 292
Acceleration/Deceleration Sensor: Service and Repair
REPLACEMENT
1. Refer to the illustration and remove the floor console. 2. Remove the G sensor and bracket.
CAUTION: Take care not to drop or subject the G sensor to a severe impact.
3. Reverse procedure to install.

Page 6548
Page 776
Wire Color Codes
the marking color.

Page 5227

Page 165
Grounding Markings

Page 3027

Page 5967
Wire Color Codes
the marking color.

Page 6894
Door Light
Page 2542
database number.
Page 4562

Page 1883
Catalytic Converter: Service and Repair Federal

Page 4799
1. Turn up the carpet under the brake pedal. 2. Start the engine, depress the brake pedal with
approximately 500 N (110 lbs.) of force, and measure the clearance between the brake pedal and
the
firewall. The standard value (C) is 100 mm (3.94 inch) or more.
3. Turn back the carpet.

Refrigerant Pressure Sensor / Switch: Testing and Inspection
DUAL PRESSURE SWITCH (LOW PRESSURE SWITCH)
1. Turn back the adaptor valve handle all the way and install it to the low pressure side service
valve. 2. With the gage manifold low pressure service valves closed, connect the gage manifold
high pressure side charging hose to the adaptor valve. 3. Tighten the adaptor valve handle and
open the service valve. 4. If there is continuity between the dual pressure switch terminals when
the low pressure side pressure is at the level shown in the illustration at left
when the dual pressure switch is on, the switch is functioning normally. If not, replace the switch.
Page 2263

Constant Velocity Joint Boot: Mechanical Specifications
Opening Dimension Of The Special Tool (MB991561) or equivalent:
When The Birfield Joint (B.J.) Boot Band Is Crimped:
Small.....................................................................................................................................................
....................................2.9 mm (0.114 inch) Big...................................................................................
.........................................................................................................3.2 mm (0.126 inch)
Crimped Width Of The B.J. Boot

Band...............................................................................................................................2.4-2.8 mm
(0.094-0.110 inch) Clearance Between The B.J. Boot (Larger Diameter Side) And The Stepped
Phase Of The B.J. Housing................0.05 -1.55 mm (0.0020-0.0610 inch) Setting Of Double Offset
Joint (D.O.J.) Boot Length: 77-83 mm (3.03-3.27 inch)
Page 4583
REMOVAL
INSPECTION
Service and Repair
Amplifier: Service and Repair
Amplifier - Removal And Installation
Removal
Installation

Page 2326
Wire Color Codes
the marking color.

Page 3983
Page 1434
Valve Guide: Service and Repair
1. Remove the snap ring from the exhaust valve guide. 2. Using the press, remove the valve guide
toward the cylinder block. 3. Rebore the valve guide hole of the cylinder head so that it may fit to
the press fitted oversize valve guide.
Guide Hole Diameters

0.05 O.S.: 11.05 - 11.07 mm (0.4350 - 0.4358 inch) 0.25 O.S.: 11.25 - 11.32 mm (0.4429 - 0.4457
inch) 0.50 O.S.: 11.50 - 11.52 mm (0.4528 - 0.4535 inch)
NOTE: Do not install a valve guide of the same size again.
4. Press fit the valve guide until it protrudes 14 mm (0.55 inch) from the cylinder head top surface
as shown in the illustration.
NOTE: -
When press fitting the valve guide, work from the cylinder head top surface.
- Pay attention to the difference in length of the valve guides. The intake side is 45.5 mm (1.79
inch) and the exhaust side is 50.5 mm (1.99 inch).
- After installing the valve guides, insert new valves in them to check for sliding condition.
Specifications

........................................... 35 Nm (26 ft. lbs.)
Page 3504


Page 1305
NOTE (1)
Page 3562
examples 1 and 2.)
low.

Page 6703
Wire Color Codes
the marking color.

Page 4016
the arrow.

Page 4233

Cylinder Head and Valve R & R - Manual Revision
Valve: Technical Service Bulletins Cylinder Head and Valve R & R - Manual Revision
NO.: TSB-97-11-008 DATE: May, 1997 MODEL: 1997 Montero
SUBJECT: CYLINDER HEAD AND VALVE REMOVAL, INSTALLATION, AND INSPECTION

CORRECTIONS - SERVICE MANUAL REVISION
PURPOSE This bulletin contains corrections for cylinder head and valve removal, installation, and
valve inspection (exhaust valve face service limit) in the Engine Overhaul section of the 1997
Montero Service Manual, Volume 1.
AFFECTED VEHICLES 1997 Montero
1997 Montero Service Manual, Volume 1, Page 11B-32, 11B-34, 11B-35

Inspection
switch.
Continuity Check
Locations

Page 4962
(Part 2 Of 2)

Page 6971
on actual vehicles.
Wire Color Codes
Page 220
Part 2 Of 3
Page 6086
Grounding Markings

Page 1914

Page 5363
CAUTION:

Page 132
Grounding Markings

Page 2913

Page 5171

Torque 1.5 ft.lb

Page 5456
Ball Joint: Service and Repair Dust Shield Replacement

Upper
REMOVAL

Precaution
PURPOSE
AFFECTED VEHICLES

Page 2009
INSPECTION
Using Scan Tool

Page 2318

SENSOR VIEW

Page 3408

Page 2671
INSPECTION
Using Scan Tool

HARNESS INSPECTION
(A1 - 37)
control module.
Page 5311
Power Steering Fluid: Fluid Type Specifications
ATF Dexron II
Page 4585
the arrow.

Page 723
Wire Color Codes
the marking color.

Page 1097
Engine Oil: Fluid Type Specifications
Temperatures below 38°C (100°F)
..................................................................................................................................................... SAE
5W-30 Preferred Temperatures above -18°C (0°F) ............................................................................
......................................................................................... SAE 10W-30
NOTE Use only engine oils displaying the Engine Oil Licensing and Certification System (EOLCS)
certification mark on the container. If these oils are not available, those with an American
Petroleum Institute (API) classification SH EC II or SH/CD EC II can be used. The SAE grade
number indicates the viscosity of the oil. A proper SAE grade number should be selected according
to ambient temperature.
Page 4900
Load Compensator: Adjustments
LOAD SENSING SPRING LENGTH CHECK
1. Park the vehicle on a level ground. The vehicle should be unloaded and supported only by
wheels.
NOTE: Never support the vehicle with jacks or other similar means.
2. With the lever pressed all the way to the load-sensing proportioning valve side, check whether
the length of the spring (the length between its
ends) shown in the illustration is at the standard value. The standard value is 224-228 mm (8.8-9.0
inch).
3. If the spring length is not within the standard value, loosen the bolt attaching the support and
adjust the distance moving the support.
Page 1166
Page 589
Wire Color Codes
the marking color.

Locations

SENSOR VIEW

Page 2782


Locations

Page 7138
Defogger Relay
Page 1160

PURPOSE
(ECU).
AFFECTED VEHICLES

Service and Repair
Removal
Installation

Page 2405
Grounding Markings

Page 3413
1996 Montero, Volume 1, page 13A-177. The following applies to all engines:
Page 4844
1997 Montero Sport Service Manual, Volume 1, Page 27-6 Add the new special tool information as
shown.
Page 2080
Grounding Markings

Page 5576
Torsion Bar: Service and Repair
REMOVAL
INSTALLATION
a. Torsion bar assembly installation (4).
1. Check the identification marks at the end of the left and right shock absorbers.
R --> for right side. L --> for left side.

Page 3097
Grounding Markings

Page 6867
Grounding Markings

Page 5289
Page 2538
reprogramming.
Page 4936
Vacuum Brake Booster: Testing and Inspection
OPERATIONAL TEST
For simple checking of the brake booster operation, carry out the following tests: 1. Run the engine
for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually
becomes higher when depressed
succeeding times, the booster is operating properly, if the pedal height remains unchanged, the
booster is defective.
2. With the engine stopped, Step on the brake pedal several times. Then step on the brake pedal
and start the engine. If the pedal moves downward
slightly, the booster is in good condition. If there is no change, the booster is defective.
3. With the engine running, Step on the brake pedal and then stop the engine. Hold the pedal
depressed for 30 seconds. If the pedal height does not
change, the booster is in good condition, if the pedal rises, the booster is defective. If the above
three tests are okay, the booster performance can be determined as good. If one of the above
three tests is not okay at last, the check valve, vacuum hose, or booster will be defective.
Page 125
retry.
ECU check error
Attachment A

Page 6423
2. Turn the control switch to SET. 3. Check that deceleration continues while the switch is pressed,
and that when it is released the constant speed at the time when it was released
becomes the driving speed.
NOTE: When the vehicle speed reaches the low limit [approximately 40 km/h (25 mph)] during
deceleration, the automatic speed control will be canceled.
Auto-cruise Control Cancellation Check and Check of Return to the Set Speed Before Cancellation
1. Set the cruise speed control. 2. Check that there is a return to ordinary driving when either of the
operations below is performed.
Page 6166
2. Insert fishing line [Dia 0.8 mm (.03 in.)] between the body and the side garnish and grip each
end of fishing line. Cut through adhesive materia by
pulling line in a sawing motion and remove the side garnish.
3. When the side garnish is fastened with a clip, pull the side garnish toward you to remove the clip.
CAUTION: -
To reuse the side garnish, remove it by pulling fishing line along the body so as not to damage the
edges of the side garnish.
- If it is hard to cut through adhesive material, heat it to approx. 40 degrees C (104 degrees F).
4. Peel off the tape.
5. Wipe the body surface with a rag moistened with isopropyl alcohol so that the surface is clean
and free of grease.
REMOVAL OF BLIND RIVET
Use a drill [Dia 4.0-5.5 mm (.16 - .22 in.)] to break the rivet by drilling a hole, and remove the blind
rivet.
INSTALLATION OF SIDE GARNISH AND OVER FENDER

Page 1362
2. Attach the bearing cap on the cylinder block as shown. 3. Tighten the bearing cap bolts to 74 Nm
(54 ft. lbs.) in the sequence shown. 4. Check that the crankshaft rotates smoothly.
5. Check the end plate. If it exceeds the limit value, replace the thrust bearing.
6. Using the seal installer tool No. MD998718, or equivalent, press fit a new crankshaft rear oil seal
into the oil seal case.
Page 6578
B. CAUTION: SRS
frame.
F. CAUTION: SRS
G. WARNING: SRS
H. Danger: Poison.
medical attention.
J. CAUTION: SRS
key.
Page 6066
PARTS INFORMATION
Page 6157

procedures apply.
Page 197
INSPECTION
one.
troubleshooting.
Page 1750
Fan Clutch: Testing and Inspection
- Check that the fluid in the fan clutch is not leaking at the case joints and seals. If the fluid quantity
decreases due to leakage, the fan speed will decrease and engine overheating might result.
- When a fan attached to an engine is turned by hand, it should give a sense of some resistance. If
fan turns lightly, it is faulty.
- Check bimetal strip for damage.

Page 6996

Page 6841
Brake Lamp: Description and Operation
- Battery positive voltage is constantly applied to the stop light switch through multi-purpose fuse
No. 17.
- When the brake pedal is depressed, the stop light switch turns on and the stop lights illuminate.
Page 2459
Wire Color Codes
the marking color.

Page 2580
OPERATION
Page 6909

(Part 1 Of 2)
(Part 2 Of 2)
Page 6444
Cruise Control Switch: Component Tests and General Diagnostics
Power Switch Check
1. Turn the ignition switch to ON. 2. Check that the indicator light within the switch illuminates when
the main switch is turned to ON.
Operations Check
Cruise Control Setting Check
1. Switch ON the main switch. 2. Drive at the desired speed above approximately 40 km/h (25
mph). 3. Turn the control switch to the SET position. 4. Check that when the switch is released the
speed is the desired constant speed.
NOTE: If the vehicle speed decreases to approximately 15 km/h (9 mph) below the set speed,
because of climbing a hill for example, the cruise control will be canceled.
Speed Increase Setting Check
1. Set to the desired speed. 2. Turn the control switch to RESUME. 3. Check that acceleration
continues while the switch is pressed, and that when it is released the constant speed at the time
when it was released
NOTE: Even if, during acceleration, the vehicle speed reaches or exceeds the high limit
[approximately 200 km/h (124 mph)], acceleration will continue, however, when the switch is
released, the set speed ("memorized speed") will become the high limit of the vehicle speed.
Speed Reduction Setting Check
1. Set to the desired speed.

Page 832
Impact Sensor: Locations

Page 660

Page 287

Page 2160


Page 7097
RELAY VIEW
Turn Signal And Hazard Flasher Unit H

Page 6984
on actual vehicles.
Wire Color Codes
Page 2935
Wire Color Codes
the marking color.

Precautions

PURPOSE
AFFECTED VEHICLES

Fuel Gauge Unit
Float Point "F" ......................................................................................................................................

................................................................ 3 ± 2 Ohm Float Point "E" ..................................................
................................................................................................................................................ 110 ± 7
Ohm
Specifications
Operating Pressure

Page 1653
- Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and
tensioner must be kept free from oil and water. Do not immerse parts in cleaning solvent.
- If there is oil or water on any part, check the front case oil seal, camshaft oil seal and water pump
for leaks.
3. Use end yolk holder and two pulley holding pins tool Nos. MB990767 and MD998715, or
equivalents to loosen/tighten the camshaft sprocket
bolt.
4. If the auto tensioner rod is fully extended, set it in the retracted position with the following
procedure:
a. Set the auto tensioner in a vice.
b. Slowly close the vice to force the rod in until the set hole (A) of the rod is lined up with the set
hole (B) of the cylinder. c. Insert a wire 1.4 mm (0.055 inch) in diameter into the set holes. d.
Remove the auto tensioner from the vice.
5. When installing the timing belt, proceed as follows:
a. Move the timing mark of the crankshaft sprocket three teeth to slightly lower the piston below the
top dead center on the compression stroke of
the No. 1 cylinder.
CAUTION: If the camshaft sprocket is rotated with the piston at TDC on the compression stroke of
the No. 1 cylinder, the valve and piston might interfer with one another.
Page 127

Page 4746
REPLACEMENT

Specifications
Drive Belt Tensioner: Specifications
Pulley Bolt ............................................................................................................................................

............................................... 50 Nm (36 ft. lbs.)
Page 6309
CONTROL UNIT VIEW
Sunroof Control Unit G
Page 2175
on actual vehicles.
Wire Color Codes
Page 4269

Page 1426
Rocker Arm Assembly: Testing and Inspection Rocker Arm Shaft Inspection
Check the rocker arm mounting portions of the rocker arm shafts for wear or damage. Replace as
necessary.
Page 4313
DISASSEMBLY
disc, if necessary.
BEARING REPLACEMENT
Service and Repair
Compact Disc Player (CD): Service and Repair
Radio With Tape Player And CD Player - Removal And Installation
Removal
Installation

Locations
COMPONENT VIEW VIEW

Page 5594
Page 4537
Input Shaft: Service and Repair
DISASSEMBLY
ASSEMBLY
A. Ball bearing installation. (2)

Page 2734
connected.)
connector.
increased.
Page 6987
Roof Rack - Wind Noise/Paint Peeling
Roof Rack Frame: Customer Interest Roof Rack - Wind Noise/Paint Peeling
NO: TSB-98-51-003 DATE: May, 1998 MODEL: 1992-98 Montero
SUBJECT: ROOF RACK WIND NOISE/PAINT PEELING
PURPOSE
On some vehicles, the paint may begin to peel from the roof rack surface. To correct this condition,
a roof rack service kit containing side rails and cross-bars with improved paint is available. The
service kit components have also been redesigned to reduce wind noise.
Recent vehicle shipments have a new roof rack system which also has the improved paint and new
design. The new roof rack system can be identified by the four tie-down loops. (Original roof racks
have eight tie-down loops.)
The service kit cross-bars do not have tie-down loops. If a customer so desires, the original
cross-bar tie-down loops can be transferred to the new cross-bars. However, if this is done the
cross-bar filler strip must be shortened to accommodate the tie-down loops.
Typically, the original rub strips can be re-used. Do not replace the rub strips unless the original
ones are coming loose.
AFFECTED VEHICLES
1992-98 Montero models equipped with roof rack
PARTS INFORMATION
Normal warranty procedures apply.


Page 1268
Be sure that the camshaft lobe is on the flat side when performing this step.
a. If the head of the adjuster sinks when finger pressure is applied, the adjuster must be replaced.
b. If the head of the adjuster stays firm when finger pressure is applied, the adjuster is operating
normally. Do not replace the adjuster. Refer to section 11 of the appropriate service manual for
further engine diagnosis to determine the cause of the noise.
Valve Lash Adjuster Inspection (All)
Nature Code: 80B Cause Code: 220
Labor Operation Number: 11321500 Time Allowance: 0.3 hrs.
Warranty Coverage: 36 months/36,000 miles if not related to owner maintenance.
Special Warranty Information:
^ Use labor operation number 11131000 for rocker cover removal and reinstallation. (0.2 hrs. per
cover, i.e., V6 = 0.4 hrs., 4 cylinder = 0.2 hrs.)
^ Perform only when due to customer complaint and after attempt to determine if due to lack of
maintenance (i.e., overdue oil changes). If due to lack of maintenance, advise customer that
condition is their responsibility. Advise customer that a ticking noise for a short time during
warm-up is normal.
Page 1632
5. Cover the tip of a screwdriver with a cloth and apply it to the cutout in the oil seal to pry off the oil
seal.
CAUTION: Use care not to damage the crankshaft and oil seal case.
6. Using the tool, press fit a new crankshaft rear oil seal into the oil seal case. 7. Use the flywheel
stopper tool to secure the drive plate, and tighten the bolts to 72 - 76 Nm (53 - 56 ft. lbs.) when
installing the adaptor plate "B"
drive plate and adaptor plate "A".

Page 269
RELAY VIEW

Page 4486
transfer case.
transfer case.

transfer case.

Specifications
Hose/Line HVAC: Specifications
With suction hose replacement add refrigerant oil. ND-OIL 8 .............................................................
............................................................................................................................ 10 cubic cm (0.3 fl.
oz.)
Page 1560
Page 1598
high pressure side.
pressure side.
Page 1231
ASSEMBLY
Page 5345
Grounding Markings

Engine - Block Heater Update
Engine Block Heater: Technical Service Bulletins Engine - Block Heater Update
No.: TSB-01-11-002
DATE: May, 2001
MODEL: All Models
SUBJECT: ENGINE BLOCK HEATER UPDATE
This bulletin supersedes TSB-99-11-009, issued November 1999, to include block heater
information for 2001 models.
PURPOSE
Page 6870
on actual vehicles.
Wire Color Codes
Locations
Key Cylinder Lamp: Locations

Page 7150
RELAY VIEW
Defogger Timer J
Page 7053
RELAY VIEW
Taillight Relay B
Page 6794
Grounding Markings

Page 7113
Turn Signal Switch: Testing and Inspection
Turn-signal Light Switch

Page 4402


Page 5369

Page 1833
on actual vehicles.
Wire Color Codes
Page 478
OPERATION
Page 167


Ball Joint End Play Check
Tie Rod End: Testing and Inspection Ball Joint End Play Check
1. Hold the ball joint with pliers. 2. Set a caliper gage as shown in the illustration at left and
measure the displacement with the ball stud compressed.
3. If the measured displacement is over the limit, replace the ball joint.
NOTE: Even if the measured displacement is within the limit, check the ball joint starting torque.
Page 2029
increased.

Page 2844
Standard value:
Page 2332
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Specifications
Stabilizer Link: Specifications
Stabilizer Link Ball Joint Breakaway Torque
........................................................................................................................ 1.7-3.1 Nm (15-27 inch
lbs.)
Page 1774
INSPECTION
Using Scan Tool
HARNESS INSPECTION
harness. (A2 - 92)
(A1 - 83)

Page 6873
Cargo Lamp: Description and Operation
- Battery positive voltage is constantly applied to the dome light and cargo space light.
- When the dome light switch or the cargo space light switch is set to the ON position, the dome
light or cargo space light always illuminates. When the switch is set to the DOOR position, the
dome light or cargo room light illuminates when any door is opened.
Page 237
INSPECTION
measurements

Page 5203


Page 2788
sensor.

Rotor: Testing and Inspection
Rotor
1. Check the continuity between the rotor coil slip rings and replace the rotor it the resistance value
is not the standard value.
Standard value: Approx. 3-5 ohms.
Rotor
2. Check the continuity between the slip ring and core and if there is continuity, replace the rotor.
Page 2069
Removal
Installation
Page 6997
Grounding Markings

Page 4194
bearing, measure the rotation torque.
4. Position the special tool in the side bearing seat of the gear carrier, and then select a drive
pinion rear shim of a thickness which
corresponds to the gap between the special tools.
NOTE: -
Be sure to clean the side bearing seat thoroughly. When positioning the special tool, check that the
cut-out sections of the special tool are in the position shown in the illustration, and also check that
the special tool is in close contact with the side bearing seat.
- When selecting the drive pinion front shims, keep the number of shims to a minimum.
5. Fit the selected drive pinion rear shim(s) to the drive pinion, and then use the special tool to
press-fit the drive pinion rear bearing inner
race.
D. Drive pinion bearing preload adjustment. (-)
Adjust the drive pinion rotation torque by using the following procedure:
Without Oil Seal 1. Insert the drive pinion front shim(s) between the drive pinion spacer and the
drive pinion rear bearing inner race.
2. Use the special tools to tighten the companion flange to the specified torque.
NOTE: Do not install the oil seal.
3. Measure the drive pinion rotation torque (without the oil seal).
Page 2139
Page 4664
on actual vehicles.
Wire Color Codes
Page 6892
on actual vehicles.
Wire Color Codes
Page 5596
ASSEMBLY
Page 7032
Parking Lamp: Electrical Diagrams

Page 4265


Specifications
...................................................................... 1.12 W
Page 2842
Intake Air Temperature Sensor: Description and Operation
OPERATION
- The intake air temperature sensor functions to convert the temperature of the air drawn into the
engine to a voltage, and to input that voltage as a signal to the engine control module. The engine
control module, based upon those signals, then corrects the amount to fuel injection, etc.
within the unit, to the intake air temperature sensor, it passes through the intake air temperature
sensor, which is a type of resistor, and is grounded as the engine control module.
Page 4963

Cargo Lamp: Diagram Information and Instructions
Page 3492
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Specifications
Page 6183
Make sure to pay close attention to the measurements shown on the template in step 2. The new
rectangular- shaped hole should start at the bottom of the original "T"-shaped hole, and extend
exactly 21 mm above the top of the "T". The 21 mm dimension is critical for proper striker
operation.
4. Reinstall the mat into the cargo area.
5. Fold down the third-seat and verify that latches operate properly and the seat is secure when
latched. If the seat does not latch securely, go to step 6.
6. If the seat latches operate improperly and/or the seat is not secure, use the following steps to
correct the condition.
a. Loosen (but do not remove) the third-seat bracket bolts (A,B,C in the illustration) on the wheel
rear wheel housing.
b. Latch the third-seat securely into the striker.
c. Tighten bolt A.
d. Tighten bolt B.
e. Release the third-seat latch from the striker and fold up the seat.
f. Tighten bolts C.
g. Latch third-seat again and verify that the latches operate properly.
PARTS INFORMATION
No parts are required for this campaign.
CAMPAIGN CLAIM INFORMATION
Claims for this campaign must be entered as "C"-type claims using the "E-5" option on your
Diamond Network Warranty System's main menu.
Rear Cargo Area Mat Modification
CAMPAIGN CLAIM SAMPLE - CAMPAIGN C9805RXX

Page 2754

SENSOR VIEW

Blower Motor Switch: Testing and Inspection
INSPECTION
BLOWER SWITCH
Page 2906
the standard value.

the system.
Specifications
License Plate Lamp: Specifications
License plate light ................................................................................................................................
......................................................................... 10 W
Page 711

control module.
Page 1576
Service and Repair
Page 399
Multi Meter
INSPECTION
Using Scan Tool
HARNESS INSPECTION
NOTE:
Battery Check
Battery: Testing and Inspection Battery Check
Battery Inspection
Battery Visual Inspection - 1
The battery contains a visual test indicator which gives blue signal when an adequate charge level
exists, and white signal when charging is required.
Battery Visual Inspection - 2
Make sure ignition switch is in Off position and all battery feed accessories are Off. 1. Disconnect
ground cable from battery before disconnecting (+) cable. 2. Remove battery from vehicle.
CAUTION: Care should be taken in the event battery case is cracked or leaking to protect hands
from the electrolyte. A suitable pair of rubber gloves (not the household type) should be worn when
removing battery by hand.
3. Inspect battery carrier for damage caused by loss of acid from battery. If acid damage is present,
it will be necessary to clean area with a solution
of clean warm water and baking soda. Scrub area with a stiff bristle brush and wipe off with a cloth
moistened with ammonia or baking soda in water.
4. Clean top of battery with same solutions as described in step 3. 5. Inspect battery case and
cover for cracks. If cracks are present, battery must be replaced. 6. Clean the battery post with a
suitable battery post cleaning tool. 7. Clean the inside surfaces of the terminal clamps with a
suitable battery terminal cleaning tool. Find place damaged or frayed cables and broken
terminals clamps.
8. Install the battery in vehicle. 9. Connect (+) and (-) cables to battery in the order of mention.
10. Tighten the clamp nut securely.

Page 5770
Refrigerant: Service and Repair Charging, Recovery and Refilling Oil
1. With the handles turned in all the way (valves closed), install the adaptor valve to the
low-pressure side of the gage manifold. 2. Connect the charging hose (blue) to the adaptor valve.
3. Connect the quick joint (for low pressure) to the charging hose (blue). 4. Connect the quick joint
(for low pressure) to the low pressure service valve.
NOTE: The low-pressure service valve should be connected to the compressor.
CAUTION: 1. Use tools that are designed for R-134a. 2. To connect the quick joint, press section A
firmly against the service valve until a click is heard. When connecting, run your hand along the
hose while pressing to ensure that there are no bends in the hose.
5. Close the high and low pressure valves of the gage manifold. 6. Install the vacuum pump
adaptor to the vacuum pump. 7. Connect the vacuum pump plug to the vacuum pump adaptor. 8.
Connect the charging hose (yellow) to the R-134a connection port of the vacuum pump adaptor. 9.
Tighten the adaptor valve handle (valve open).
10. Open the low pressure valve of the gage manifold. 11. Turn the power switch of the vacuum
pump to the ON position.
NOTE: Even if the vacuum pump power switch is turned on, the vacuum pump will not operate
because of the power supply connection in step (7).
Engine - Valve Lash Adjuster Cleaning Procedure
Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Valve Lash Adjuster Cleaning
Procedure
NO: TSB-99-11-006 DATE: June, 1999 MODEL: See below
SUBJECT: VALVE LASH ADJUSTER CLEANING
PURPOSE
This bulletin contains cleaning procedures for valve lash adjusters. In many cases, cleaning valve
lash adjusters can extend their service life. Mitsubishi Motors strongly suggests cleaning and
inspecting lash adjusters before considering lash adjuster replacement.
AFFECTED VEHICLES
All models equipped with valve lash adjusters
PROCEDURE
! CAUTION
A Valve lash adjusters are precision mechanisms. Do not allow them to become contaminated by
dirt or other foreign substances. Do not attempt to disassemble valve lash adjusters. Use only
clean diesel fuel to clean valve lash adjusters.
1. Prepare three containers. Place enough diesel fuel into each container to cover a lash adjuster
when it is standing upright.
^ Container A will be used to clean the outside of the lash adjuster.
^ Container B will be used to clean the inside of the lash adjuster.
^ After cleaning the adjuster, use Container C to fill it with clean diesel fuel.
2. Place the lash adjuster into container A and clean its outside surface, using a nylon brush if
necessary.
Page 2484
Wire Color Codes
the marking color.

Page 3632
Spark Plugs

Limit : 1.3 mm (0.051 in.)
a plug cleaner and
Spark Plug Cable

Page 2633

Page 5714
DISASSEMBLY AND REASSEMBLY

DISASSEMBLY SERVICE POINT
Page 4018
A. Overdrive switch/position light switch connector case removal. (1)
Use a flat-tip (-) screwdriver or similar tool to remove the overdrive switch/position light connector
case from the terminal.
B. Selector knob removal. (2)
1. Press the knob cover downwards. 2. Remove the front and back mounting screws, and then
remove the selector knob from the selector lever.
C. Overdrive switch removal. (3)
Use a flat-tip (-) screwdriver or similar tool to remove the overdrive switch.
INSPECTION
1. Check the detent plate for wear. 2. Check the bushing for wear or damage. 3. Check the spring
for damage or deterioration.
Overdrive Switch
Page 5977

CAUTION:
Removal Steps
Reserve tank
work.
Page 6474

Specifications
Case Adapter: Specifications
SEALANTS
Adapter Gasket:
Transfer Side: Mitsubishi Genuine Sealant Part No. MD997740 or Equivalent Transmission Side:
Mitsubishi Genuine Sealant Part No. MR166584 or Equivalent
Page 6341
1997 Montero Service Manual, Volume 2, Page 47 Correct the description for D-35 as shown:
Page 2886
Standard value:
oxygen sensor.
Page 787

SENSOR VIEW

Specifications
IDLE SPEED
700 RPM Man & Auto

Page 5403
Page 5942

- Clock Spring
- Air Bag Module
Service Precautions
table.
SRS-ECU Connector
PURPOSE
(ECU).
AFFECTED VEHICLES

Page 958
Alignment: Service and Repair Rear Suspension
ON-VEHICLE SERVICE
The rear suspension assembly must be free of worn, loose or damaged parts prior to measurement
of rear wheel alignment. Standard value:
Toe-in: 0 mm (O inch) Camber: 0 °
NOTE: Toe-in and camber are set at the factory and cannot be adjusted.
Page 1932
Page 2623
OPERATION
Page 710
Ignition switch-ST
HARNESS INSPECTION
module. -
NOTE: -

Page 3486
Wire Color Codes
the marking color.

Page 1773
OPERATION
engine is cold.
Specifications

........................................... 35 Nm (26 ft. lbs.)
Page 6798
Wire Color Codes
the marking color.

Page 5695
Locations
Fusible Link: Locations
Name Symbol
Fusible Links 1-7 A
Page 3713
Specifications
Bracket Bolt .........................................................................................................................................

............................................................................................................................... 5 Nm ( 3.6 ft. lbs.)
Page 2779

Page 6350
1999 Montero Service Manual, Volume 2, Page 90-137 Replace the circuit diagram crossed-out on
the previous page of this bulletin with the new corrected diagram shown.
Page 5995
Page 2537
3. If the correct database is selected, press ENTER. If not, press ESC to cancel and return to the
main menu.
4. A progress monitor displays during data transfer to the PC memory card.
5. After the data has been transferred to the PC memory card, this message displays.
reprogramming.
Specifications
Clutch Fluid: Specifications
Note:
Specification Conforming to DOT3 or DOT4

Specifications
IDLE SPEED
700 RPM Man & Auto

Locations

Page 3374
Wire Color Codes
the marking color.

Page 3889
Fluid Pump: Service and Repair
DISASSEMBLY
A. Drive gear / driven gear removal. (4 & 5)
1. Put mating marks on the side of removed gears for their reassembly in correct direction. (Use a
felt marker or equivalent.)
INSPECTION OF DRIVE GEAR AND DRIVEN GEAR
Body Clearance
1. Measure the clearance between the driven gear and oil pump body with a feeler gauge while
pushing the driven gear strongly toward the
opposite side.
Page 1525
of oil pan as specified in illustration.
diameter.
12 Nm (7 - 9 ft. lbs.).
California
REPLACEMENT
1. Remove the under skid plate, undercover. 2. Remove the warm up three way catalytic converter.
3. Drain the engine oil. 4. Remove the lower oil pan bolts.
Page 4620
REMOVAL
INSTALLATION
Locations

Page 744
HARNESS INSPECTION
NOTE: -
- 92)
control module. -
(A3 - 90, A7 - 19)

Page 7000
on actual vehicles.
Wire Color Codes
Locations
Ambient Temperature Sensor / Switch HVAC: Locations

Page 5543
the vehicle.
rear springs.
NOTE:
Page 1307
Lifter / Lash Adjuster: Testing and Inspection
NOTE: Directly after starting the engine or while the engine is running, if an abnormal sound
(knocking) is heard and it seems to be coming from the lash adjuster and doesn't stop, carry out
the following inspection.
1. Check the engine oil and replenish or replace the oil if necessary.
NOTE: -
If there is a small amount of oil, air is sucked in through the oil strainer and gets into the oil
passage.
- If the amount of oil is greater than normal, oil is splashed by the crank, and a large amount of air
is mixed into the oil.
- Air and oil will not separate easily in oil that has deteriorated, and the amount of air mixed into the
oil will increase.
If the air mixes with the oil, due to the above reasons, and gets into the high pressure chamber of
the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is
open and the lash adjuster will over-compress, resulting in an abnormal noise when the valve
closes. This is the same effect as if the valve clearance is adjusted (by mistake) to be too large.
Here, if the air inside the lash adjuster is released, then the operation has returned to normal.
2. Start the engine and gently race [1] the engine several times (10 times or less). If the abnormal
noise is stopped by the racing, air has been released
from the high pressure chamber, and the functioning of the lash adjuster has returned to normal.
NOTE: -
Parking on a slope for a long period will decrease the amount of oil inside the lash adjuster, and
then air may get into the high pressure chamber when starting the engine.
- After parking the vehicle for long periods, the oil drains out of the oil passage, and it takes time for
the oil to be supplied to the lash adjuster, so air can get into the high pressure chamber.
3. If the abnormal noise is not stopped by racing the engine, check the lash adjuster by the
following procedure:
a. Stop the engine. b. Set the engine No. 1 cylinder to the compression top dead center position.
Page 2723
Grounding Markings

Specifications
Door/Trunk Ajar Indicator/Lamp: Specifications
Door ajar warning light .........................................................................................................................
...................................................................... 1.12W
Page 4679
Page 6593
Wire Color Codes
the marking color.

Page 392
Grounding Markings

Diagrams
Page 236

Specifications
Engine Oil Pressure: Specifications
The manufacturer does not provide this specification.
Page 1189
Maintenance Required Lamp/Indicator: Electrical Diagrams

Page 2573

Page 2149
Standard value:
oxygen sensor.
Page 2284

Page 1322
Rocker Arm Assembly: Testing and Inspection Rocker Arm Shaft Inspection
Check the rocker arm mounting portions of the rocker arm shafts for wear or damage. Replace as
necessary.
Page 5861
1992-96 Expo/Expo LRV Service Manual, Volume 1, Page 52B-23 Add the new SRS
troubleshooting information to the indicated service manual page as shown.
Page 5364
Locations

Page 3407
Page 6759
Speedometer Head: Locations

Page 591
OPERATION
Page 6621


Page 2769
increased.

Page 2947

Page 5032
This bulletin contains a battery application guide, replacement battery part numbers, and cold
cranking amps specifications (CCA) for all Mitsubishi vehicles.
AFFECTED VEHICLES 1991-99 3000GT 1995-96 3000GT Spyder 1983-88 Cordia 1992-96
Diamante 1993-95 Diamante Wagon 1990-2004 Eclipse 1996-2004 Eclipse Spyder 1992-96
Expo/Expo LRV 1985-2004 Galant 2002-04 Lancer 2003 Lancer Evolution 2004 Lancer Sportback
1989-1994 Mighty Mits 1985-2002 Mirage 1986-2004 Montero 1997-2004 Montero Sport 2003-04
Outlander 1986-94 Precis 1988-90 Sigma 1983-89 Starion 1983-89 Tredia 1982-96 Truck
19878-90 Van/Wagon
Page 5408
Page 618

Page 815
Wire Color Codes
the marking color.

Page 2028
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Page 5381
Steering Gear: Fluid Type Specifications
Automatic Transmission Fluid "DEXRON II" used for bearing, O-ring and oil seal.
Page 3312
Intake Air Plenum: Service and Repair
Removal steps
Page 3837
washer to the gear.
to the gear.
as follows:

Page 493


Page 4973
REPLACEMENT

Page 5422
Tie Rod End: Specifications
Tie Rod End Ball Joint End Play Limit

................................................................................................................................................ 1.5 mm
(.059 inch)
Tie Rod End Ball Joint Breakaway Torque

............................................................................................................................... 1 - 3 Nm (9 - 26
inch lbs.) Tie Rod End Locking Nuts ...................................................................................................
................................................................. 44 Nm (33 ft.lbs.)
Front Planetary Gear
Planetary Gears: Service and Repair Front Planetary Gear
DISASSEMBLY
ASSEMBLY
A. Thrust race / thrust bearing installation. (6 & 7)
B. Thrust race installation. (5)
1. Install the thrust race to the planetary gear assembly while aligning its claws with the holes of the
front planetary gear.
Page 5934
INSPECTION
one.
troubleshooting.
Page 2983

Page 1142
driver injury.
Page 3093
Leak Detection Solenoid: Locations
COMPONENT VIEW
Evaporative Emission Ventilation E
Solenoid
Page 1945
relay as shown:
Page 6893
Wire Color Codes
the marking color.

Page 2863

Page 47
RELAY VIEW

Page 2617
Grounding Markings

Page 1805
Radiator: Capacity Specifications
Performance ........................................................................................................................................
.................................. 200,900 kJ/h (190,476 BTU/h)
Page 3173
Technician Safety Information
Drum Brake System: Technician Safety Information
WARNING:
- Brake fluid may irritate eyes and skin. In case of contact, take the following actions:
- Eye contact - rinse thoroughly with water.
- Skin contact - wash with soap and water. If ingested consult a physician immediately.
CAUTION: WHEN SERVICING BRAKE PARTS, DO NOT CREATE DUST BY GRINDING OR

SANDING BRAKE LININGS, BY CLEANING BRAKE PARTS WITH A DRY BRUSH OR WITH
COMPRESSED AIR. MANY EARLIER MODEL OR AFTERMARKET BRAKE PARTS MAY
CONTAIN ASBESTOS FIBERS WHICH CAN BECOME AIRBORNE IF DUET IS CREATED
DURING SERVICING. BREATHING DUST CONTAINING ASBESTOS FIBERS MAY CAUSE
SERIOUS BODILY HARM. A WATER DAMPENED CLOTH OR WATER BASED SOLUTION
SHOULD BE USED TO REMOVE ANY DUST ON BRAKE PARTS. EQUIPMENT IS
COMMERCIALLY AVAILABLE TO PERFORM THIS WASHING FUNCTION. THESE WET
METHODS WILL PREVENT FIBERS FROM BECOMING AIRBORNE.
Page 3902
Limit: 1.51 mm (0.0594 inch)
the limit.
ASSEMBLY
transmission case.
Specifications
Standard ..............................................................................................................................................
....................................................................................................................... 890 kPa (127 psi)
.................................................................................................................................................. 100
kPa (14 psi)
Page 6643

Page 6956
RELAY VIEW
Horn Relay C
Specifications
Volt Meter Gauge: Specifications
Voltage meter resistance .....................................................................................................................
........................................................... 380 - 460 Ohm
Page 3965
on actual vehicles.
Wire Color Codes
Page 2825
Battery - Application Guide/Cold Cranking Amp Specs.
Battery: Technical Service Bulletins Battery - Application Guide/Cold Cranking Amp Specs.
No: TSB-03-54-011 DATE: December, 2003 MODEL: See Below
SUBJECT: BATTERY APPLICATION GUIDE & COLD CRANKING AMPS SPECIFICATIONS
PURPOSE
Diagrams
Cowl: Diagrams
FRONT DECK
1. The cowl top panel has a 3 block structure, with the front, outer and inner as used previously. 2.
The cowl top inner panel is welded to the front pillar outer and inner in order to increase the joining
strength.
3. The front deck has newly been provided with a front deck crossmember to reduce steering wheel
vibration and to increase safety in the event of an
impact.
4. To further increase rigidity of the base of the front pillar section, the upper frame has been
changed from the previous block structure to a single
structure with a U-shaped cross-section.

Page 2783
on actual vehicles.
Wire Color Codes
Parasitic Draw
Battery: Specifications Parasitic Draw
Parasitic Draw
Information not supplied by the manufactuer

Page 5661
RELAY VIEW

Page 4425

Master Cylinder Bleeding
Brake Bleeding: Service and Repair Master Cylinder Bleeding
4.
Brake Booster - Push Rod Adjustment
Vacuum Brake Booster: Technical Service Bulletins Brake Booster - Push Rod Adjustment
NO.: TSB-97-35-003 DATE: July, 1997 MODEL: See below
SUBJECT: CLEARANCE BETWEEN BRAKE BOOSTER PUSH ROD & PRIMARY PISTON -
PURPOSE A new special tool, MB991714 "Push Rod Adjusting Gauge" is now available for
adjusting the clearance between the brake booster push rod and the primary piston. This bulletin
contains instructions on how to use this special tool
In the affected service manuals, delete the brake booster push rod-to-master cylinder piston
clearance specifications. Replace the "Clearance Between Brake Booster Push Rod and Primary
Piston Adjustment" procedure with the procedure in this bulletin.
AFFECTED VEHICLES
1992-97 3000GT 1994-97 Galant
1992-96 Diamante 1993-97 Mirage
1995-97 Eclipse 1992-97 Montero
1997 Eclipse Spyder 1997 Montero Sport
1992-96 Expo/Expo LRV
AFFECTED SERVICE MANUALS
1992-96 3000GT, Volume 1, pages 35-3, 35-88, and 3589 1997 3000GT, Volume 1, pages 35-3,
35A-25, and 35A-26 1992-96 Diamante, Volume 1, pages 35-3, 35-63, and 35-64 1995 Eclipse,
Volume 1, pages 35A-4 and 35A-26 1996 Eclipse, Volume 1, pages 35A-3 and 35A-24 1997
Eclipse/Eclipse Spyder, Volume 1, pages 35A-3, 35A-27, and 35A-28 1992-96 Expo/Expo LRV,
Volume 1, pages 35-4, 35-94, and 35-95 1994-95 Galant, Volume 1, pages 35A-3 and 35A-22
1996 Galant, Volume 1, pages 35A-3, 35A-19, and 35A-20 1997 Galant, Volume 1, pages 35A-4,
35A-20, and 35A-21 1993-96 Mirage, Volume 1, pages 35-4, 35-61, and 35-62 1997 Mirage,
Volume 1, pages 35A-4 and 35A-19 1992-95 Montero, Volume 1, pages 35A-3, 35A-20, and
35A-21 1996 Montero, Volume 1, pages 35A-3, 35A-21, and 35A-22 1997 Montero, Volume 1,
pages 35A-3, 35A-21, and 35A-22 1997 Montero Sport, Volume 2, pages 35A-19 and 35A-38
affected service manual pages to reference the following instructions:
CLEARANCE BETWEEN BRAKE BOOSTER PUSH ROD AND PRIMARY PISTON

ADJUSTMENT
(1) Set the special tool to the master cylinder.

Page 4234

Page 4312
Page 2084
Wire Color Codes
the marking color.

Page 2298

SENSOR VIEW

Page 2763
Page 2177
Page 4834
Brake Pad: Testing and Inspection Rear
NOTE: The brake pads have indicators that contact the brake disc when the brake pad thickness
becomes 2 mm (0.08 inch), and emit a squealing sound to warn the driver. Always replace the
pads on both sides, and also the brake pads for the wheels on the opposite side at the same time.
If there is a significant difference in the thicknesses of the pads on the left and right sides, check
the sliding condition of the piston, lock pin and guide pin.
- Check the brake pad thickness through the caliper body check port. The standard value is 9 mm
(0.35 inch) and the limit is 2.0 mm (0.079 inch).
CAUTION: Do not wipe the special grease from the lock pin. Do not contaminate the lock pin.
Page 4143
NOTE:
Page 2060
on actual vehicles.
Wire Color Codes
Page 251


Seats - Heater Circuit Locator & Diagrams Revised
Seat Heater: Technical Service Bulletins Seats - Heater Circuit Locator & Diagrams Revised
SUBJECT: CORRECTED CIRCUIT AND CONFIGURATION DIAGRAMS FOR HEATED SEAT -

PURPOSE This bulletin contains corrections to the configuration diagrams and circuit diagrams
relating to the heated seat.
AFFECTED SERVICE MANUAL 1997 Montero Service Manual, Volume 2, Pages 46, 47, 190, 191
1998 Montero Service Manual, Volume 2, Pages 80-14, 90-139 1999 Montero Service Manual,
Volume 2, Pages 80-13, 90-137

Page 3833
Clutch: Service and Repair Rear Planetary Gear, Output Shaft and First & Reverse Brake
DISASSEMBLY

Locations

Page 6445
California
HARNESS INSPECTION


Generator Stator - Removal Procedure Revision
Stator: Technical Service Bulletins Generator Stator - Removal Procedure Revision
NO.: TSB-97-16-004 DATE: May, 1997 MODEL: See below
SUBJECT: GENERATOR STATOR REMOVAL - SERVICE MANUAL REVISION
PURPOSE The procedure for removing the stator from the generator are incorrectly described in
the affected service manual pages. This bulletin contains the proper generator stator removal
procedure for affected vehicles.
AFFECTED VEHICLES 1992-97 Montero 1995-97 Eclipse and Eclipse Spyder 1994-97 Galant
AFFECTED SERVICE MANUALS 1992-95 Montero, Volume 1, page 16-15 1996 Montero, Volume
1, page 16-15 1997 Montero, Volume 1, page 16-15 1995 Eclipse, Volume 1, page 16-28 1996
Eclipse/Eclipse Spyder, Volume 1, page 16-28 1996 Eclipse/Eclipse Spyder, Volume 1, page 16-24
The generator stator removal procedure applies to all affected service manual pages.
Engine - Spark Knock/Ping Diagnostic's
Fuel: All Technical Service Bulletins Engine - Spark Knock/Ping Diagnostic's
SERVICE TIP: When diagnosing an engine pinging condition, always check for carbon deposits,
which may have occurred due to fuel grade or quality and/or the customer's driving style. If
necessary, clean combustion deposits from the pistons and combustion chamber. Recommend to
customers to always use the correct grade of fuel for their model vehicle.
Page 3945
Part 3 Of 3
Service and Repair
Trailing Arm Bushing: Service and Repair
Use the special tool to replace the rear lower arm rear bushing.
Page 1361
a. Measure the crankshaft journal diameter and confirm its classification from the table. In the case
of a bearing supplied as a service part, its
identification color is painted at the position shown.
b. The cylinder block bearing bore diameter identification marks are stamped at the position shown
in the illustration from the front of the engine,
beginning at No 1.
c. Select a proper bearing from the above table on the basis of the identification data confirmed
under items (a) and (b).
Example: -
If the measured value of a crankshaft journal outer diameter is 63.996 mm, the journal is classified
as "1 " in the table. In case the crankshaft is also replaced by a spare part, check the identification
color painted on the new crankshaft. If it is yellow, for example, the journal is classified as "1".
- Next, check the cylinder block bearing hole identification mark stamped on the cylinder block. If it
is "I", read the "Identification color for the spare bearing" column to find the identification color of
the bearing to be used. In this case, it is "pink".
d. Install the bearing halves with oil groove in the cylinder block side. e. Install the bearing halves
without oil groove on the bearing cap side. f.
Install the thrust bearings on both sides of the No. 3 bearing with the grooves facing outward.
Page 6899

Locations
Data Link Connector: Locations
COMPONENT VIEW VIEW
Data Link Connector B

Page 5605
SNOW TIRE RECOMMENDATIONS FOR 1997 MODELS
Page 3247
Fuel Injector: Oscilloscope Patterns and Waveforms
(1) Disconnect the injector intermediate harness, and connect the special tool (harness connector
MD998474).
(2) Connect the oscilloscope probes according to the details given in the table above.
Connect the analyzer special patterns pickup to ECM terminals (1), (2), (3), (14), (15) and (16).


Resistance/Torque

Page 128
CONTROL UNIT VIEW
Page 1281
NOTE
CAUTION
operation.
CAUTION
rocker arm.
NOTE
1. Stop the engine.
Steering Wheel: Technical Service Bulletins Steering - Cautions for Steering Angle Adjustment
No: TSB-00-37A-001
DATE: October, 2000
MODEL: See Below

adjustment.
MANUAL REVISIONS
Page 2010
HARNESS INSPECTION
(A5 - 92)
control module. -
(A1 - 81, A2 - 85)
Page 3835
Limit: 1.51 mm (0.0594 inch)
the limit.
ASSEMBLY
transmission case.
Page 5395
NOTE: The balls must be inserted so that there is no clearance between them.
3. Set the remaining seven balls in the circulator, and install the circulator to the rack piston.
i. Valve housing installation (20). 1. Apply specified automatic transmission fluid to the seal ring of
the rack piston.
2. Insert the valve housing. 3. Rotate the main shaft until the rack piston moves to the neutral
position (center).
j. Adjusting plate/adjusting bolt installation (24 & 25). 1. Install the adjusting plate so that the
beveled part is facing downward. 2. Use a feeler gage to measure the clearance between the
adjusting bolt and the cross-shaft.
Standard value: 0-0.05 mm (0-.002 inch)
3. If the clearance is exceeded the standard value, replace with a suitable adjusting plate.
k. Cross-shaft/adjusting bolt lock nut installation (26 & 27).
Install the cross-shaft to the side cover, and then temporarily tighten the adjusting bolt lock nut.
l. Side cover and cross-shaft assembly installation (29). Install the side cover assembly (with the
cross-shaft) to the gear box.
NOTE: Apply specified automatic transmission fluid to the teeth and shaft areas of the rack piston,
and apply multipurpose grease to the oil seal lip.
CAUTION: Do not rotate the side cover during installation. Take care not to damage the cross-shaft
oil seal.
Page 2282

Page 2655
Standard value:
oxygen sensor.
Page 2257
connected.)
connector.
increased.
Page 4532
INSPECTION
transfer case.
transfer case.
transfer case.

Page 2407


Corrections
DTCs.
NOTE:

Page 774


Page 6549
Multi Meter
Page 3267

Page 6872
Dome, Cargo Space And Reading Lights

Page 2666


Page 401

Page 5870
1994-95 Galant Service Manual, Volume 1, Page 52B-23 Add the new SRS troubleshooting
Page 2513
on actual vehicles.
Wire Color Codes
Page 5986
Page 3481

Page 3048
OPERATION
Page 5148
on actual vehicles.
Wire Color Codes
No.: TSB-95-52B-002

Specifications
Sun Gear: Specifications
Planetary Sun Gear Bushing Inner Diameter:
Limit .....................................................................................................................................................
................................... 24.07 mm (0.948 inch)
Antenna Motor: Technical Service Bulletins Power Antenna - Motor Inspection Procedure
Revisions

numbering.

Locations
Tachometer Connector: Locations
COMPONENT VIEW VIEW
Engine Speed Detection Connector A

Page 568

Locations

Page 4893
Hydraulic Assembly: Service and Repair
REPLACEMENT
1. Drain the brake fluid into a suitable container. 2. Remove the brake pipe connections. 3. Remove
the Hydraulic Unit (HU).
CAUTION: -
The HU is heavy. Take care when removing it.
- Do not loosen or remove any HU nuts or bolts.

- Do not drop or subject the HU to any shock.
- The HU must not be turned upside down or laid on its side.
- Ensure hydraulic system is bleed. See: Brake Bleeding/Service and Repair
- Test the HU for proper operation. See: Testing and Inspection

Page 3678


Page 529
Grounding Markings

Page 2702
Page 1910
memory.
III. Error List

Page 1314
NOTE
CAUTION
operation.
CAUTION
rocker arm.
NOTE
1. Stop the engine.
NO.: TSB-96-55-006
DATE: May, 1996
MODEL: All with A/C
SUBJECT: A/C REFRIGERANT SERVICE INFORMATION
PURPOSE
Beginning January 1, 1996, the production of CFC (chlorofluorocarbon) refrigerants such as

R12(Freon) was prohibited in the United States as part of an international agreement to protect the
atmosphere. New HFC (hydrofluorocarbon) refrigerants such as R134a are now used in all
new-vehicle automotive air conditioning systems instead of the formerly-used R12.
This bulletin describes:
^ refrigerants and their availability,
^ differences between A/C systems, refrigerants, and lubricants,
^ retrofitting R12 systems to use R134a,
^ recovery and recycling of refrigerants,
^ storing and transferring recycled refrigerant,
^ typical causes of A/C system contamination, and
^ disposal of contaminated refrigerant.
Refrigerants and Their Availability
In 1993, auto makers began using R134a refrigerant in new-vehicle air conditioning systems. Yet in
early 1996 there are still an estimated 90-150 million vehicles in service that use R12 as a
refrigerant in their systems. Now that R12 can no longer be produced legally, the price of this
refrigerant is rising, and cheap substitutes and illegal supplies are appearing on the market.
As of this writing, there are only three EPA-approved alternatives to R12. These are R134a, R401c,
and FRIGC. These refrigerants, including R12 are not interchangeable and cannot be mixed in a
system. Because of the high cost of R134a and the rising prices of diminishing field stocks of R12,
other refrigerants, sometimes called "drop-in" refrigerants, are appearing on the market. Some of
these are mixtures that can contain impure R12 or R22 (a commercial refrigerant not used in auto
A/C systems), or mixtures of flammable hydrocarbons such as butane and propane. Impure R12
can have adverse effects on A/C systems and service equipment.
System Differences
A system that is charged with one type of refrigerant can become contaminated when serviced with
equipment that is used for other refrigerants. The system can be damaged by these contaminants;
resulting in costly repairs; and when the contaminants get into the servicing equipment they can
spread to other vehicles like a virus. To prevent this; industry standards have been developed so
that an A/C system designed for one kind of refrigerant cannot accept equipment designed for
another. Underhood labels on each vehicle clearly state the factory charge by type and amount of
refrigerant. Fittings on R12 systems are not the same as those on R134a systems. Unlike R12
systems which typically use threaded service fittings for the high and low sides; R134a systems
use quick coupler fittings without external threads. The high side has a 16 mm O.D. fitting while the
low side has a 13 mm O.D. fitting. R12 system fittings are 7/16"-20; R134a fittings have 1/2"-16
Acme threads.
Since R134a is made up of smaller molecules than R12; R134a tends to leak through hoses easier
than R12. For this reason, service hoses for the two refrigerants have different specifications.
Service hoses for R12 are marked "SAE J2196". The low-side hose is solid blue or black with a
blue stripe; the high-side hose is solid red; or black with a red stripe. The utility hose is either solid
yellow or white; or black with yellow or white stripe. Service hoses for R134a are labeled "SAE
J2196-R134a" and are color-coded as follows: solid blue with black stripe for the low-side hose,
solid red with a black stripe for the high-side hose, and solid yellow with black stripe for the utility
hose.
Refrigerant Differences
R12(Freon) and R134a are not compatible and must never be mixed. R134a is less efficient than
R12. Higher operating pressures and larger system components make up for the difference in
performance. Leakage is of greater concern with R134a because its molecules are smaller than
those of R12 and it can seep through the rubber hoses more easily. R134a mixed with
high-pressure air can be ignited under certain conditions by a spark or open flame. R134a is an
irritant and also very corrosive. It will tarnish and discolor any metal with which it comes in contact
in liquid form.
R12 is highly toxic when exposed to flame. The product of its combustion is phosgene gas, a
powerful irritant to human tissue. R12 gas released into the atmosphere rises to the stratosphere
where it can linger for decades. In the stratosphere, a layer of ozone acts as a sunscreen that
protects Earth from the sun's ultraviolet rays. The R12 reacts with the ozone to produce
compounds that cannot filter the sunlight, allowing more ultraviolet radiation to reach Earth. More
ultraviolet rays can cause increase in skin cancer, more eye cataracts, reduced immunity to
disease, damage to vegetation, and increased amounts of ozone at ground level where smog is
formed.
Page 6581
Teck Line.
Page 4183
A. Rear axle shaft assembly removal. (5)
Pull out the right and left axle shafts by about 70 mm (3 inch). If it is difficult to pull out, use the
special tools.
B. Rear propeller shaft removal. (7)
Make the mating marks on the flange yoke of the rear propeller shaft and the companion flange of
the differential case.
C. Differential carrier removal. (10)
Remove the mounting nuts and strike the lower part of differential carrier assembly with a piece of
timber several times to loosen it, and then remove the assembly.
CAUTION: -
Do not remove the uppermost nut but keep it loosened all the way to the stud bolt end.
- Use care not to strike the companion flange.
INSTALLATION
A. Rear propeller shaft installation. (7)
Align the mating marks on the flange yoke and the companion flange to install the rear propeller
shaft.
NOTE: Operational steps after assembly as follows: 1. Bleed air from brake lines. 2. Adjust parking
brake lever stroke. 3. Fill differential with gear oil.
Inspection Before Disassembly

Page 6990
License Plate Lamp: Service and Repair
License Plate Light - Removal And Installation

Removal
To remove follow the steps listed in the image and note the following
License Plate Light Garnish Removal
Step 5: License Plate Light Garnish Removal
1. Take off the waterproof film and remove the license plate light garnish mounting nuts. 2. Remove
the clips with a flat-tip (-) screwdriver, and then remove the license plate light garnish together with
the socket assembly.
Installation

Page 1021
Timing Belt: Testing and Inspection
Replace belt if any of the following conditions exist. 1. Hardening of back rubber-back side is glossy
without resilience and leaves no indent when pressed with fingernail.
2. Cracks on rubber backing. 3. Cracks or peeling of canvas. 4. Cracks on tooth bottom. 5. Cracks
on side of belt.
6. Abnormal wear of belt sides. The sides are normal if they are sharp as if cut by a knife.
7. Abnormal wear on teeth. 8. Tooth missing and canvas fiber exposed.

Locations
Sunroof / Moonroof Module: Locations

Diagrams
Cowl: Diagrams
FRONT DECK
1. The cowl top panel has a 3 block structure, with the front, outer and inner as used previously. 2.
The cowl top inner panel is welded to the front pillar outer and inner in order to increase the joining
strength.
3. The front deck has newly been provided with a front deck crossmember to reduce steering wheel
vibration and to increase safety in the event of an
impact.
4. To further increase rigidity of the base of the front pillar section, the upper frame has been
changed from the previous block structure to a single
structure with a U-shaped cross-section.

Replacement
Wheel Hub: Service and Repair Replacement

REMOVAL

Page 1523
of the oil pan as shown.
diameter.
8. Install the oil pan to the cylinder block within 30 minutes after applying the sealant. 9. Tighten the
oil pan mounting bolts in the order shown to 6 Nm (4 ft. lbs.).
CAUTION: The bolt holes for bolts 15 and 16 in the illustration are cut away on the transmission
side, so be careful not to insert these bolts at an angle.
Locations

Page 6686

Page 1141
B. CAUTION: SRS
frame.
F. CAUTION: SRS
G. WARNING: SRS
H. Danger: Poison.
medical attention.
J. CAUTION: SRS
key.
Page 2793

SENSOR VIEW

Page 4058

Fillpipe Restrictor: Description and Operation
Fillpipe Restrictor
The fillpipe restrictor is used to prevent leaded fuel from being added to the fuel tank. The gasoline
pump for unleaded fuel has a smaller nozzle. The fillpipe restrictor will only allow the unleaded type
nozzle to be inserted into the fuel tank.
Blower Motor Resistor: Testing and Inspection
RESISTOR
Use an ohmmeter to measure the resistance between the terminals indicated below. The condition
can be considered satisfactory if the value measured at this time is equivalent to the standard
value.
Standard value:
Page 5341
Component View
Page 6495
Cigarette Lighter: Electrical Diagrams
Cigarette Lighter
Page 3809
1997 & 1998 Montero Service Manuals, Volume 1, Page 23B-57 Change the forward clutch piston
Page 5953


Page 3007
Wire Color Codes
the marking color.

Page 3722
on actual vehicles.
Wire Color Codes
Specifications
Case: Specifications
Transmission Case ..............................................................................................................................

............................................ 36 Nm (26 ft. lbs.) Case Adapter ............................................................
...................................................................................................................... 36 Nm (26 ft. lbs.)
Page 1394
1. Mark the cylinder number on the side of the connecting rod big end for correct reassembly. 2.
Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.
3. Remove the snap rings from the piston pin.
4. When removing the piston pin, heat the piston to approximately 70° C (158° F) and pull out the
piston pin.
NOTE: The clearance between the piston and the piston pin is an almost tight fit at normal
temperature. Therefore, be sure to heat the piston before pulling out the piston pin. In addition,
note that the piston is hot after heating.
5. When installing the piston pin, heat the piston pin to approximately 70° C (158° F) and set the
snap ring on one side first. Be sure to install the
snap ring with the shear droop directed toward the inside.
6. With the front mark of the connecting rod and that of the piston located on the same side, insert
the piston pin. 7. After insertion of the piston pin, set the other snap ring.
NOTE: -
Apply an ample coat of engine oil to the periphery of the piston pin and the hole of the connecting
rod small end.
- The clearance between the piston and the piston pin is an almost tight fit at normal temperature.
Therefore, be sure to heat the piston before inserting the piston pin.
- In addition, note that the piston is hot after heating.
Page 2279

SENSOR VIEW

Suspension - Shock Absorber Leakage Inspection
Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber
Leakage Inspection
No: TSB-10-33-001
DATE: January, 2010
MODEL: All Models
SUBJECT: INSPECTION CRITERIA FOR LEAKING SHOCK ABSORBERS
PURPOSE
This TSB provides instructions for shock absorber inspection, and criteria for determining oil leak
severity to help dealers judge whether a shock absorber requires replacement.
AFFECTED VEHICLES All Models
DESCRIPTION
When inspecting shock absorbers, oil seen on the surface is not always an indication of a seal
failure requiring shock replacement.
Shock absorber seals perform 3 functions:
1. seal the shock absorber oil inside the cylinder.
2. prevent dust entering the cylinder.
3. spread an even film of oil to lubricate the piston rod and seal.
Shock absorbers lose a small amount of oil during use and this is considered normal. As the piston
rod travels through compression and rebound strokes during shock absorber operation, a film of oil
adheres to its surface, bypassing the seal. This helps lubricate and extend the life of the seal.
During compression of the shock, oil is scraped off the piston rod by the seal's dust lip and
accumulates on the outer surface of the shock. This small amount of oil does not always indicate a
defective shock absorber.
PROCEDURE
SHOCK ABSORBER VISUAL INSPECTION FLOWCHART
Use the Shock Absorber Visual Inspection Flowchart when inspecting shock absorbers. If there is
oil visible on the shock's surface, use the Oil Leak Severity Guidelines to determine the extent of
the leak, and proceed according to comments in the Remarks column.
SHOCK ABSORBER VISUAL INSPECTION FLOWCHART

Page 5890
INSPECTION
Air Bag Module
If any improper part is found during the following inspection, replace the air bag module with a new
one. Dispose of the old one according to the specified procedure.
CAUTION Never attempt to measure the circuit resistance of the air bag module (squib) even if you
are using the specified tester. If the circuit resistance is measured with a tester, accidental air bag
deployment will result in serious personal injury. 1. Check pad cover for dents, cracks or
deformities. 2. Check the air bag module for dents, cracking or deformation. 3. Check hooks and
connectors for damage, terminals for deformities, and harness for binds. 4. Check air bag inflator
case for dents, cracks or deformities. 5. Install the air bag module on the steering wheel or dash to
check alignment.
Clock Spring
If, as result of the following checks, even one abnormal point is discovered, replace the clock
spring with a new one. 1. Check connectors and protective tube for damage, and terminals for
deformities. 2. Visually check the case for damage.
Page 537
sensor.

Specifications
Page 5963
Grounding Markings

Page 3258
relay as shown:
Page 3124
EGR Control Solenoid: Testing and Inspection Diagnostic Inspection
TROUBLESHOOTING HINT
If the results of EGR solenoid on-vehicle and off vehicle inspections are normal but the diagnostic
trouble code for EGR system failure is displayed check the EGR valve, vacuum hose and EGR
passage for blockage.
INSPECTION
Using Scan Tool
HARNESS INSPECTION
STEP 1. Check for continuity between the EGR solenoid and the MFI relay. -
EGR solenoid connector: Disconnected
NOTE: -
Touch the circuit tester probes to both ends of the harness.
STEP 2. Check for an open circuit or a short-circuit to ground between the EGR solenoid and the
EGR solenoid connector: Disconnected
- Engine control module connector: Disconnected OK: STOP NG: Repair the harness. (A1 - 6)
Function Test
Load Compensator: Testing and Inspection Function Test
1. Connect pressure gages to the input and output ports of the load sensing proportioning valve. 2.
Bleed the system and disconnect the spring at the support side.
3. Place the spring so that it is in parallel with the load-sensing proportioning valve, and then pull in
the direction indicated by arrow "A" so that its
length "H" is 226.7 mm (8.9 inch) (the length between its ends) is as noted below. -
With an input pressure of 10 MPa (1422 psi) the output pressure should be 6.14-7.04 MPa
(873.3-1001.3 psi)
- With an input pressure of 18 MPa (2560 psi) the output pressure should be 7.94-9.24 MPa
(1129.3-1314.2 psi)
NOTE: At this time the lever is pressed all the way to the load-sensing proportioning valve side.
4. Check that the output fluid pressure is within the standard value at this time. 5. In the same
manner as in step 3., check that the output fluid pressure is within the standard (correct) value
when the spring length H is 257.7 mm
(10.2 inch) relative to the load-sensing proportioning valve input fluid pressure. -
With an input pressure of 18 MPa (2560 psi) the output pressure should be 13.1-15.1 MPa
(1863.3-2147.7 psi)
6. After making the check, install the spring. Disconnect the pressure gages from the load-sensing
proportioning valve and bleed the hydraulic system
of air.
Page 1797

Page 5420
1987-96 Truck (2-wheel drive models)
Page 4660

Page 2410
Page 3567

SENSOR VIEW

Synthetic Resin Parts - Heat Resistance Specifications
Exterior Moulding / Trim: All Technical Service Bulletins Synthetic Resin Parts - Heat Resistance
Specifications
NO.: TSB-96-42A-015
DATE: July, 1996
MODEL: All Models
SUBJECT: SYNTHETIC RESIN PARTS: HEAT RESISTANCE TEMPERATURE

SPECIFICATIONS
PURPOSE
This bulletin contains detailed information about heat resistance temperatures on synthetic resin
parts. The table lists all synthetic resin parts, the material name, the heat resistance temperatures,
and their major locations on the vehicle.
AFFECTED VEHICLES
All Mitsubishi vehicles.
BODY REPAIR MANUAL REFERENCES
All Body Repair Manuals, Section 5: Synthetic resin Parts

Page 571


Page 5371

Page 6663
Grounding Markings

Page 5383
Steering Gear: Description and Operation
Type: Ball and nut, torsion bar type (integral type).
INSPECTION
BLOWER SWITCH
Page 2850

Page 6510

Page 1274
3. While gently pushing down the internal steel ball using stiff wire (0.5 mm diameter), move the
plunger through 5 to 10 strokes until it slides smoothly. This will remove dirty oil from the lash
adjuster and loosen the plunger.
! CAUTION
The steel ball spring is extremely weak. If the wire is pushed in with too much force, the lash
adjuster will be damaged.
If the plunger remains stiff or the mechanism appears to be abnormal, replace the lash adjuster.
4. Remove the lash adjuster from container A. Then gently push down the steel ball and push the
! CAUTION
On DOHC engines, point the oil hole toward container A. Do not point the oil hole toward anyone.
5. Place the lash adjuster in container B. Then gently push down the internal steel ball using stiff
wire (0.5 mm diameter). Move the plunger through 5 to 10 strokes until it slides smoothly. This will
clean the lash adjuster's pressure chamber.
Page 5264
Wire Color Codes
the marking color.

Page 3841
Clutch: Service and Repair One-Way Clutch, A/T
DISASSEMBLY
INSPECTION
1. While holding planetary sun gear, turn the one-way clutch clockwise to see that the clutch turns
smoothly and turn it counterclockwise to see
that the clutch is locked.
NOTE: -
- If the one-way clutch turns counterclockwise while it doesn't turn clockwise, the one-way clutch
may have been installed in the reverse direction.
ASSEMBLY

Page 5359
B. CAUTION: SRS
frame.
F. CAUTION: SRS
G. WARNING: SRS
H. Danger: Poison.
medical attention.
J. CAUTION: SRS
key.
Page 2653
HARNESS INSPECTION
NOTE: -

Page 1901
Components

Procedure
DVD-ROM drive.
Page 291
3.4 - 3.6 volts.
G-sensor.
Page 2575

Page 4266
on actual vehicles.
Wire Color Codes

Page 5541
AFFECTED VEHICLES
1995-99 Montero
PROCEDURE

Rollover Valve: Testing and Inspection
If the sound of the float valve moving (knocking sound) can be heard when the valve assembly is
gently shaken up and down, then the valve is okay.
Page 6101
Neutral Safety Switch: Technical Service Bulletins A/T - Park/Neutral Position Switch Adjustment
V4AW2 A/T.
23A-45
Page 6065
Page 4356
Universal Joint: Specifications Rear Axle

............................................ 5 mm (0.20 inch)
Page 6891


Page 2331
harness. (A3 - B1)
(A1 - Ground)
harness. (A2 - 89)
Page 4165
A. Front propeller shaft removal. (8)
Make mating marks on the flange yoke of the rear propeller shaft and on the companion flange of
the differential case.
INSPECTION
Free-Wheel Engage Switch
The switch is normal if there is continuity when the shaft is pushed in and no continuity when the
shaft is released.
INSTALLATION
A. Free-wheeling clutch assembly installation. (22)
After installing the free-wheeling clutch assembly, select a spacer so that the clutch gear play
(bearing looseness) is within the standard value.
B. Front propeller shaft installation. (8)
Install the front propeller shaft so that the mating marks on the flange yoke and differential carrier
companion flange are aligned.
C. Vacuum hose installation. (1)
Install the vacuum hoses so that the identification colors match those of the actuator assembly
nipples.
NOTE: Operational steps after installation as follows: 1. Install under cover. 2. Fill gear oil.
Inspection Before Disassembly

Page 5795
RELAY VIEW

Page 2451

SENSOR VIEW

Page 1617
Page 2199
position sensor.

Page 5301
Idler Arm Starting Torque Check
1. Give 10 hard swing to the idler arm. 2.
Measure the idler arm swing resistance with a spring scale.
Standard value:
1. After shaking the ball joint stud several times, install the nut to the stud and use the special too
joint. Standard value:
Tie rod end: 1 - 3.0 Nm (9 - 26 inch lbs.) Idler arm: 0.5 - 2.0 N (4 - 17 inch lbs.)
2. When the measured value exceeds the standard value, replace the tie rod assembly. 3. When
the measured value is lower than the standard value, check that the ball joint swings smoothly
without excessive play. If so, it is
possible to use that ball joint.
INSTALLATION
a. Pipe/tie rod end, inner/tie rod end, outer installation (2, 3 & 4).
Page 5512
Stabilizer Link: Service and Repair

1. Remove the clip ring and the dust cover.
2. Apply multipurpose grease to the lip and inside of the dust cover.
3. Use vinyl tape to tape the stabilizer link where shown in the illustration, and then install the dust
cover to the stabilizer link. 4. Secure the dust cover by the clip ring.
NOTE: When installing the clip ring, align the ends at a 90° angle from the axis of the stabilizer link.
Page 120
Page 4763
(Part 2 Of 2)

California
HARNESS INSPECTION

Page 739
Wire Color Codes
the marking color.

Adjustments
Hood: Adjustments
BOLTED PANEL FIT AND ADJUSTMENT
HOOD
ADJUSTMENT OF HOOD FIT
1. Adjust the longitudinal and lateral positions of the hood by utilizing the oblong holes in the hinge.
2. Turn the hood bumpers either left or right to adjust the height of the hood.
3. Adjust the linking of the hood latch and hood striker by loosening the hood latch mounting bolt
and moving the hood latch.
Hood latch mounting bolt tightening torque: 9 Nm (7 ft.lbs.)

Brake Fluid Level Sensor/Switch: Testing and Inspection
The brake fluid level sensor is in good condition if there is no continuity when the float surface is
above "A" and if there is continuity when the float surface is below "A."
Page 3239
on actual vehicles.
Wire Color Codes
V4AW2 A/T.
23A-45
Locations

Alternator Brush: Testing and Inspection
1. Measure the length of the brush protrusion shown in the illustration and replace the brush if the
measured value is below the limit value.
Limit: 2.0 mm (0.8 in) or below.
Brush Replacement
2. The brush can be removed if the solder of the brush lead wire is removed. 3. When installing a
new brush, push the brush in the brush holder as shown in the illustration and solder the lead wire.
Page 4810
on actual vehicles.
Wire Color Codes
Page 151
RELAY VIEW

Page 2874
Grounding Markings

Service and Repair
Seals and Gaskets: Service and Repair
REPLACEMENT
1. Disconnect the propeller shaft from the transfer. 2. Using a flat-tip (-) screwdriver, remove the oil
seal. 3. Using the special tool, tap the transfer oil seal into the transfer. Note in illustration the
direction of installation of transfer oil seal. 4. Apply a coating of the transmission oil to the lip of the
oil seal.
Transmission oil: Hypoid gear oil SAE 75W-90 or 75W-85W conforming to API classification GL-4.
Page 2272
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A2 - 87)
- 92)
Page 6720
Multi Meter
Page 6834

Page 5442
1996 & 1997 Montero Service Manuals, Volume 1, page 37A-36 1998 & 1999 Montero Service
Manuals, Volume 2, page 37A-37 2000 Montero Service Manual, Volume 2, page 37A-33
Page 3808
1997 & 1998 Montero Service Manuals, Volume 1, Page 23B-13 Add the new forward clutch piston
stroke measuring tool as shown.
Locations

Page 3235

Page 121
main menu.
reprogramming.
Page 3463
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A1 - 92)
control module. -
Page 3756
Page 1809
Radiator: Service and Repair
REPLACEMENT
Refer to the illustration for the service procedures, noting the following: 1. Drain the engine coolant.
2. Remove the under cover. Refer to Body and Frame. 3. Remove the air cleaner. 4. Reverse
procedure to install, being sure to check and refill the A/T fluid, if necessary.
Rocker Arm Inspection
Rocker Arm Assembly: Testing and Inspection Rocker Arm Inspection
1. Check the roller surface and replace the rocker arm if recessary, damage or heat seizure is
observed. 2. Check roller rotation and replace the rocker arm if uneven rotation or roller backlash is
observed. 3. Check the inside diameter and replace the rocker arm if damage or seizure is
observed.
Locations
Audible Warning Device: Locations

Troubleshooting
Leak Detection Solenoid: Testing and Inspection Troubleshooting
INSPECTION
Using Scan Tool
HARNESS INSPECTION
STEP 1. Check for continuity between evaporative emission ventilation solenoid and multiport fuel
injection relay. -
Evaporative emission ventilation solenoid connector: Disconnected
- Multiport fuel injection relay connector: Disconnected
NOTE: -
Touch the ohmmeter probes to both ends of the harness. OK: GO TO STEP 2 NG: Repair the
harness. (A1 - B1)
STEP 2. Check for an open circuit, or a short circuit to ground, between the evaporative emission
ventilation solenoid and the engine control module. -
Evaporative emission ventilation solenoid connector: Disconnected
Page 4068
on actual vehicles.
Wire Color Codes
Page 1986
on actual vehicles.
Wire Color Codes
Page 5428
Standard value:
INSTALLATION
Locations

SENSOR VIEW
Page 117
MAIN MENU
IMPORTANT
connectors.

the main menu.
Page 4875
Brake Caliper: Service and Repair Replacement
Front
NOTE:
Rear
Page 6385
Sound Proofing / Insulation: Service and Repair
ATTACHMENT OF SILENCERS
Silencers (petroleum-asphalt sheets) are attached to the upper surface of the floor and at the
interior side of the dash panel in order to absorb vibrations and shut out exhaust gas heat. If these
silencers are peeled off in the course of replacement or repair of a welded panel, cut and attach
replacement material (in the shape shown in the figure). For detailed information concerning the
locations where silencers are to be attached for individual models, refer to the manual for that
model.
1. Heat the "silencer layer" (petroleum-asphalt sheet) with a blow drier to soften it.
2. Align the silencer layer in the position where it is to be installed, and then press it down with a
roller or a block of wood so that it adheres well.
NOTE: An infrared lamp can also be used to heat both the silencer layer and the body panels (be
sure to wear gloves).
Page 6626
Maintenance Required Lamp/Indicator: Testing and Inspection
Reset Switch
After checking is completed, use the reset switch (located at the rear of the combination meter) to
switch off the warning light. Note that the warning light bulb should be removed after 100,000 miles
are registered.
NOTE: If the speedometer is to be replaced, set the new odometer to the same reading as the
odometer being removed.
Locations

SENSOR VIEW
Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions
Page 4212
5. Change the thickness of the friction disc so that the clearance (D - C) between the differential
case and the spring plate (vehicles with
limited slip differential) or friction disc (vehicles with rear differential lock) is at the standard value.
6. Remove the spring plates, spring discs, friction plates and friction disc.
7. Measure the dimension (H) from one end of the thrust washer to the other end.
8. Calculate the dimension (I) between the thrust washer contact surfaces when differential cases
(A) and (B) are combined.
(I = D + J + K)
NOTE: Dimension (D) is the distance between the spring plate contact surfaces when differential
cases (A) and (B) are combined.
9. Change the thickness of the thrust washer so that the clearance (I-H) between the thrust washer
and the differential case is at the standard
value.
NOTE: There are three sizes of new thrust washers: 1.50 mm (0.0591 inch), 1.60 mm (0.0630 inch)
and 1.70 mm (0.0670 inch).
10. Insert the thrust washer as shown in the illustration, and then select a thrust washer so that the
difference between the left and right
Page 607
INSPECTION
Using Scan Tool

HARNESS INSPECTION
harness. (A2 - 92)
(A1 - 74)
Page 6048

Page 2044
Wire Color Codes
the marking color.

Diagrams
Page 2711
Page 2641

Page 255

Headliner - Loose/Sagging
Headliner: Customer Interest Headliner - Loose/Sagging
NO.: TSB-97-52A-002 DATE: April, 1997 MODEL: 1992-97 Montero
SUBJECT: HEADLINER COMING LOOSE AND SAGGING
PURPOSE This bulletin contains procedures for repairing Montero rear headliners that come loose
and sag.
CAUSE AND REMEDY The rear headliner comes loose in the area where it attaches to the front
headliner because of insufficient attachment force. This condition can be repaired by drilling three
holes in the front and rear headliners and attaching the headliners together with three additional
clips.
REPAIR PROCEDURES
1. Remove the rear headliner. Removal procedures are in section 52A of the service manual.
2. Drill three 6.9 mm holes in the rear headliner at the locations indicated in the illustration.
3. Drill three 15 mm holes in the front headliner at the indicated locations.
4. Reinstall the rear headliner. Attach the rear headliner to the front headliner using the clips listed
in the Parts Information section of this bulletin.
PARTS INFORMATION
Page 2206
Locations

Page 3047
Page 5480
Page 3393
Wire Color Codes
the marking color.

Page 202
RELAY VIEW
Generator Relay B
Page 2043
on actual vehicles.
Wire Color Codes
Page 3128
4. Reset the vacuum pump to "0" (release vacuum).
5. Using a stop watch, measure how long it takes for the vacuum gauge to reach 51 kPa (15 in. Hg)
or more.
Standard value: 1.0 second or less
6. If it takes more than 1.0 second for the gauge to reach 51 kPa (15 in. Hg), the EGR vacuum port
may be restricted and should be cleaned.
Page 3845
ASSEMBLY
Page 4346
Install the propeller shaft to the companion flange so that the mating marks are aligned.
CAUTION: If the threads of the bolts and nuts are stained with oil or grease, they can become
loose. Completely remove oil or grease from the threads before tightening the bolts and nuts.
Page 2878
Wire Color Codes
the marking color.

Page 1236
Lug Nut Torque Patterns

Page 593
Standard value:
Page 6744

Page 2112

Page 3029
on actual vehicles.
Wire Color Codes
Page 4828
NOTE:

Page 2620
on actual vehicles.
Wire Color Codes
Page 535
OPERATION
engine is cold.
Page 5867
1992-95 Montero Service Manual, Volume 1, Page 52B-22 Add the new SRS troubleshooting
Page 4835
Brake Pad: Service and Repair
1. Remove the lock pin and guide pin. Lift the caliper assembly and retain with wire. 2. Remove the
pad and wear indicator assembly. 3. Remove the pad assembly, clip and outer shim. 4. Reverse
procedure to install, ensuring that the brake drag force is within specifications. See: Brake
Caliper/Testing and Inspection
Page 4662

Page 706
on actual vehicles.
Wire Color Codes
Page 2007
Page 768

SENSOR VIEW

Page 3832
up as illustrated.
Ball Joint Dust Cover - Revised Grease Application
Ball Joint: Technical Service Bulletins Ball Joint Dust Cover - Revised Grease Application
No.: TSB-01-37A-004 DATE: December, 2001 MODELS: 1992-2000 Montero
SUBJECT: BALL JOINT DUST COVER GREASE APPLICATION (MONTERO) - SERVICE

MANUAL REVISION
PURPOSE
Ball joint installation procedures in affected service manuals do not include grease application. To
prevent premature wear of the ball joint dust cover, grease must be applied to the inside and top of
the dust cover during installation. This bulletin contains ball joint grease specifications and
application instructions.
AFFECTED SERVICE MANUALS 1992-95 Montero Service Manual, Volume 1, pages 37A-3, -22,
-27, -39, -41 1996 & 1997 Montero Service Manuals, Volume 1, pages 37A-3, -18, -19, -23, -35, -36
1998 & 1999 Montero Manuals, Volume 2, pages 37A-3, -18, -19, -24, -36, -39 2000 Montero
Service Manual, Volume 2, pages 37A-3, -18, -19, -23, -32, -33, -35
1992-95, 1996, & 1997 Montero Service Manuals, Volume 1, page 37A-3 1998, 1999, & 2000
Montero Service Manuals, Volume 2, page 37A-3
Page 3370
Grounding Markings

Page 4582
Shifter Transfer Case: Service and Repair
Page 5683
RELAY VIEW

Page 6808
Volt Meter Gauge: Service and Repair Oil Pressure Gage, Inclinometer and Voltage Meter
Disassembly Steps
Disassembly
Reassembly

Page 4992
NOTE: -
Page 4656
CONTROL UNIT VIEW

Page 411
A (Float point "F") ................................................................................................................................

........................................................ 119.3 (4.69) in. B (Float point "E") ..............................................
........................................................................................................................................ 255.0
(10.03) in.
Page 6738

Page 4610
INSPECTION
the ground.
Page 6733
Point F:.................................................................................................................................................
..................................................3 ± 2 Ohms Point E:...........................................................................
...................................................................................................................110 ± 7 Ohms
touching stopper.
Standard value:
A:..........................................................................................................................................................
..........................................119.3 mm (4.69 in.) B:................................................................................
..................................................................................................................255.0 mm (10.03 in.)
Specifications
..................................................................... 1.12 W
Page 1926
Page 5549
OIL LEAK SEVERITY GUIDELINES
This chart shows the differences between oil visible on the shock absorber that is considered
normal, and leakage that may indicate a defective shock absorber.
This TSB provides information only. When replacing shock absorbers, refer to the LOTS for repair
operation numbers and labor times.
DO NOT replace shock absorbers categorized in level 1.
Shock absorbers categorized in level 2 or 3 should be replaced. DO NOT replace shock absorbers
as an axle set unless BOTH show level 2 or 3 leakage. Replace leaking shock absorbers only.
Page 4189
B. Side bearing inner race removal. (13)
Use the special tools to pull out the side bearing inner races.
C. Drive gear removal. (14)
1. Make mating marks on the differential case and drive gear. 2. Loosen the drive gear mounting
bolts in diagonal sequence to remove the drive gear.
D. Self-locking nut removal. (16)
Use the special tool to hold the companion flange, and then remove the companion flange
self-locking nut.
E. Drive pinion assembly removal. (18)
1. Make mating marks on the drive pinion and companion flange. 2. Drive out the drive pinion
together with the drive pinion spacer and the drive pinion front shims.
CAUTION: Do not make mating marks on the contact surfaces Of the companion flange and
propeller shaft.
Restraints - Revised Clockspring Alignment Procedure
Clockspring Assembly / Spiral Cable: Technical Service Bulletins Restraints - Revised Clockspring
Alignment Procedure
No.: TSB-08-52B-001
DATE: March, 2008
Model: All (exc. Montero Sport)

SUBJECT: ALIGNMENT PROCEDURE FOR CLOCK SPRING NEUTRAL POINT - SERVICE
MANUAL REVISION
PURPOSE
A modified clock spring has been adopted for Service Parts on affected vehicles as of September
2007. New and old style parts are interchangeable. This TSB advises the procedures for alignment
of the neutral point of the new clock spring when a part is replaced.
AFFECTED VEHICLES All (exc. Montero Sport)
REFERENCE INFORMATION
Page 2856
Page 3371

Page 6271
on actual vehicles.
Wire Color Codes
Page 4169
A. Differential case assembly removal. (3)
Use a hammer handle to take out the differential case assembly.
CAUTION: When taking out the differential case assembly, be careful not to drop and damage the
side bearing outer races.
NOTE: Keep the right and left side bearings and side bearing adjusting spacers separate in order
to be able to distinguish them for reassembly.
Page 4342
Page 5241
Side Slip
Measure the side slip with a side slip tester.
Standard value: (0 ± 3 mm (0 ± .12 inch)) -3 mm to +3 mm (-.12 to +.12 inch)

Page 3336
Page 2157

Page 3846
up as illustrated.
Rear Planetary Gear, Output Shaft and First & Reverse Brake
Page 6669
Page 3851
washer to the gear.
to the gear.
as follows:

Specifications
Fan Shroud: Specifications
Mounting Bolts .....................................................................................................................................

.................................................... 5 Nm (4 ft. lbs.)
Page 207
Starter Relay
Hi-Beam Indicator Lamp: Description and Operation
- When the high beams are illuminated or while passing is operating, the indicator light will
illuminate to inform the driver that the high beams are illuminated.
Page 3695
Grounding Markings

Engine Oil: Capacity Specifications
Engine Oil Refill
With Filter ............................................................................................................................................

........................................................... 5.5 Qts.(5.2L)
Note: Includes 0.5 Qts. Oil Filter and 0.5 Qts Oil Cooler
Tape Player: Diagram Information and Instructions
Page 2417
- Example 2
normal.
Page 2727
Wire Color Codes
the marking color.

Page 1558
Wire Color Codes
the marking color.

Page 1303
procedure.
NOTE
procedure.
adjuster.

PURPOSE
(ECU).
AFFECTED VEHICLES

Page 1772
Page 6691
Wire Color Codes
the marking color.

Page 3547
(A1 - D6, B1 - D6, C1 - D6)
(D1 - 11, D2 - 23, D3 - 10, D5 - 51)
(D4 - Ground)
Page 5831
1. Check pad cover for dents, cracks or deformities,
2. Check for connector damage, deformed terminal, and binding harness. 3. Check air bag inflator
case for dents, cracks or deformities. 4. Install air bag module to steering wheel to check fit or
alignment with the wheel.
Clock Spring
1. Check clock spring connectors and protective tube for damage, and terminals for deformities, 2.
Visually check the case for damage.
Federal
Muffler: Service and Repair Federal

Specifications

Page 6605
Grounding Markings

Page 4798
Brake Pedal Assy: Adjustments
1. Turn up the carpet under the brake pedal. 2. Measure the brake pedal height (A) as shown in the
illustration. The standard value (A) is 186 - 191 mm (7.3 - 7.5 inch.) 3. Turn back the carpet.
1. Loosen the lock nut to sufficiently loosen the stop light switch. 2. Adjust the brake pedal height
by turning the operating rod with pliers (with lock nut loosened). 3. After turning the stop light switch
until it contacts the pedal stop (until immediately before the brake pedal begins to move), turn the
stop light
switch back 1/2 to 1 revolution and secure with a lock nut.
CAUTION:Check that the stop light is not illuminated when the brake pedal is not depressed.
NOTE:For vehicles with automatic transmission, check the shift-lock mechanism.
While the engine is stopped, depress the brake pedal two or three times. Thus, eliminating the
negative pressure in the brake booster, press the pedal down by hand, and confirm that the free
play (B) is within the standard value range. The standard value (B) is 3 - 8 mm (0.12 - 0.31 inch).
Page 6910
Rheostat
Rheostat
Page 3272
fuel pump relay.
Alternator
Drive Belt: Specifications Alternator
When checked
A: .........................................................................................................................................................
...................... 5.0 - 7.0 mm (0.20 - 0.28 inch) B: .................................................................................
............................................................................................... 7.5 - 9.5 mm (0.30 - 0.37 inch)
When new belt is installed
A: .........................................................................................................................................................
...................... 4.0 - 5.0 mm (0.16 - 0.20 inch) B: .................................................................................
............................................................................................... 5.5 - 7.5 mm (0.22 - 0.30 inch)
When used belt is installed
A: .........................................................................................................................................................
...................... 5.5 - 6.5 mm (0.22 - 0.26 inch) B: .................................................................................
............................................................................................... 8.0 - 9.0 mm (0.31 - 0.35 inch)
TENSION
When checked .....................................................................................................................................

................................... 392 - 588 N (87 - 130 lbs.) When new belt is installed
.................................................................................................................................................... 637 -
833 N (141 - 184 lbs.) When used belt is installed
................................................................................................................................................... 441 -
539 N (98 - 119 lbs.)
Fasteners
M8 ........................................................................................................................................................
......................................... 21 Nm (15 ft. lbs.) M10 ..............................................................................
................................................................................................................. 51 Nm (38 ft. lbs.)

Page 213
side.

Page 1970
Inspection
HARNESS INSPECTION
NOTE -
Page 6302
CONTROL UNIT VIEW
Page 4419
Grounding Markings

Page 1973
Ignition Control Module: Oscilloscope Patterns and Waveforms
Wave Pattern Inspection Using an Analyzer
- Ignition coil primary signal
- Ignition power transistor control signal
Measurement method
(1) Disconnect the connector of the power transistor, and connect the special tool (test harness:
MB991348) across the disconnected connector
parts.
(2) Sequentially connect the special patterns pickup of the analyzer to each of terminal (1) (No.3 -
No.6), terminal (2) (No.2 - No.5) and terminal
(3) (No.1 - No.4) of the ignition power transistor unit connector.
Connect the analyzer special patterns pickup to ECM terminals (10), (11) and (23) for the ignition
power transistor.
Standard Wave pattern Observation Condition
Standard Wave pattern

Page 3416
Throttle Body: Specifications Mounting Bolts
Mounting Bolts
Torque 7.2 - 9.4 ft.lb

Page 5874
1996 Eclipse Service Manual, Volume 1, Page 52B-17 Add the new SRS troubleshooting
Page 76
Page 274
RELAY VIEW

Page 1468
Drive Belt: Adjustments A/C
1. Loosen the tension pulley fixing nut. 2. Adjust the belt tension using the adjusting bolt. 3. Tighten
the fixing nut. 4. Crank the engine once or more. 5. Check the belt tension.
Page 7002

Page 5421
1987-96 Truck (4-wheel drive models)

Locations
Sound Proofing / Insulation: Locations
SILENCER APPLICATION LOCATIONS
In order to reduce vibration and screen out heat from the exhaust gas, silencers (melting sheets)
are applied to the top of the floor If the silencers come off during welded panel replacement or
other repairs, cut the replacement parts in the shapes indicated and apply them in the appropriate
locations.
Page 3682

Exterior Moulding / Trim: Customer Interest Wind Noise At Upper Windshield
PURPOSE
AFFECTED VEHICLES
1992-97 Montero
PROCEDURE

Page 6644


Page 4011
Shifter A/T: Testing and Inspection
INSPECTION
1. Move the selector lever to each position and check that the lever moves smoothly and is
controlled. Check that the position indicator is correct. 2. Check that the selector lever can be
moved to each position by button operation as shown in the illustration). 3. Start the engine and
check that the vehicle moves forward when the selector lever is shifted from N to D, and moves
backward when shifted to R. 4. If there is a malfunction of the shift lever, adjust the control cable
and selector lever sleeve. Check for worn shift lever assembly sliding parts.
NOTE: To move the selector lever from the P position to any other position, first turn the ignition
key to any position other than LOCK and depress the brake pedal.
Page 3009
OPERATION
control module.
rotation.
Page 835
terminals.
INSPECTION
Page 4657
Control Module: Locations Diode (For Active Trac 4WD Circuit)
Diode Location Overviews And Views A - C
COMPONENT VIEW
Diode (for Active Trac 4WD Circuit) C

Page 4708
NOTE:
NOTE:
Page 5807
SENSOR VIEW

Page 4184
NOTE: Hold the working base in a vice, and install the differential carrier to the special tool.
FINAL DRIVE GEAR BACKLASH
With the drive pinion locked in place, measure the final drive gear backlash with a dial indicator on
the drive gear.
Standard value:
Vehicles without rear differential lock 0.13-0.18 mm (0.0051-0.0071 inch) Vehicles with rear
differential lock 0.12-0.18 mm (0.0047-0.0071 inch)
DRIVE GEAR RUNOUT
Measure the drive gear runout at the shoulder on the reverse side of the drive gear.
FINAL DRIVE GEAR TOOTH CONTACT
Check the final drive gear tooth contact by the following procedure:
1. Apply a thin, uniform coat of machine blue to both surfaces of the drive gear teeth.
Page 2444
Page 2096
Grounding Markings

Page 4646
Wire Color Codes
the marking color.

INSPECTION
Page 5064
Stator: Testing and Inspection
Stator
1. Check the continuity between the coil leads and if there is continuity, replace the stator.
Stator
2. Check the continuity between the coil and core and if there is continuity, replace the stator.
Page 6582
CAUTION:

Page 5390
g. Bearing/oil seal removal (27 & 28).
Use a socket remove the oil seal and the bearing from the valve housing simultaneously.
INSPECTION
1. Check the mainshaft for wear and damage. 2. Check the tooth surfaces of the cross shaft and
the rack piston for wear and damage. 3. Check the contact part of adjusting bolt for uneven wear.
4. Check the dust cover and the oil seal for wear and damage. 5. Check the O-rings for damage.
6. Check backlash between ball groove of rack piston and balls.
Set the rack piston to the position shown in the illustration, and then use a dial gage to measure the
backlash. Limit: 0.05 mm (.0020 inch)
7. Check pitman arm ball joint breakaway torque.
a. Move ball joint stud several times and install nut on stud. Measure ball joint breakaway torque
with special tools.
Standard value: 1-3 Nm (9-26 inch lbs.)
b. When the measured value exceeds standard value. replace the tie rod end. c. When the
excessive play. if so, it is possible

Service and Repair
Page 1123
Refrigerant: Service and Repair Charging, Recovery and Refilling Oil
1. With the handles turned in all the way (valves closed), install the adaptor valve to the
low-pressure side of the gage manifold. 2. Connect the charging hose (blue) to the adaptor valve.
3. Connect the quick joint (for low pressure) to the charging hose (blue). 4. Connect the quick joint
(for low pressure) to the low pressure service valve.
CAUTION: 1. Use tools that are designed for R-134a. 2. To connect the quick joint, press section A
firmly against the service valve until a click is heard. When connecting, run your hand along the
hose while pressing to ensure that there are no bends in the hose.
5. Close the high and low pressure valves of the gage manifold. 6. Install the vacuum pump
adaptor to the vacuum pump. 7. Connect the vacuum pump plug to the vacuum pump adaptor. 8.
Connect the charging hose (yellow) to the R-134a connection port of the vacuum pump adaptor. 9.
Tighten the adaptor valve handle (valve open).
10. Open the low pressure valve of the gage manifold. 11. Turn the power switch of the vacuum
pump to the ON position.
NOTE: Even if the vacuum pump power switch is turned on, the vacuum pump will not operate
because of the power supply connection in step (7).
Page 2708
Engine Control Module: Pinout Values and Diagnostic Parameters

Page 6627
Maintenance Required Lamp/Indicator: Service and Repair
The OEM does not provide a Maintenance Required Indicator for this model.
Page 4231
on actual vehicles.
Wire Color Codes
Page 4210
2. Inspect the contact and sliding surfaces listed below, and repair any nicks and burrs by using an
oil stone.
E. Sliding surfaces of thrust washer and case. F. Spring contacting surface of differential case. G.
Contact surfaces of outer circumference of pressure ring and inner circumference of differential
case. H. Sliding surfaces of side gear and thrust washer. I.
Sliding surfaces of hole in pressure ring and outer circumference of side gear.
J. Projection on outer circumference of pressure ring. K. Spherical surface of differential pinion

gear and inner diameter of pressure ring. L. V-shaped groove in pressure ring and V-shaped part in
pinion shaft. M. Outer diameter of pinion shaft and hole of differential pinion gear. N. Outer
circumference groove of side gear. O. Inner circumference groove of differential case.
THE FRICTION PLATE AND FRICTION DISC WARPING
Use a dial indicator to measure the amount of warping (flatness) of the friction plate and friction
disc on a surface plate by turning the plate or disc.
Limit: 0.08 mm (0.0031 inch)

Page 6463

Page 4547
Page 5735
Evaporator Core: Service and Repair
>A< EVAPORATOR INSTALLATION
When replacing the evaporator with new one, refill the evaporator with a specified amount of
compressor oil and install it to the vehicle. Compressor oil: ND-OIL 8 Quantity: 40 cubic cm (1.4
fl.oz.)
INSPECTION
- Check for damage to the evaporator fin part.
- Check for damage or collapse of the drain hose.
- Check for peeling or cracking of the insulator.

Page 3389
Grounding Markings

Page 5206
Page 2499
Wire Color Codes
the marking color.

Service and Repair
Lateral Stabilizer Rod: Service and Repair
LATERAL ROD
Removal
Installation

Page 5857
1997 Montero, Volume 1, page 52B-5
Page 2512


Page 2148
(A4 - 76, B4 - 79)
(A3 - 34, B3 - 42)
- 92)

Page 1419
procedure.
NOTE
procedure.
adjuster.

Page 4754
RELAY VIEW

Page 3938
washer to the gear.
to the gear.
as follows:

Replacement
Power Steering Pump: Service and Repair Replacement
REMOVAL
INSTALLATION
Installation in reverse order as removal, noting the following service points:
a. Pressure hose installation (4).
Connect the pressure hose so that its slit part contacts the oil pump's guide bracket.
b. After installation
1. Fill power Steering Fluid. 2. Adjust V-belt Tension. 3. Bleed power steering fluid line. 4. Check oil
pump pressure.
Page 4017
Shifter A/T: Service and Repair Overhaul
DISASSEMBLY

Page 5460
CAUTION: 1. Be sure to tie the cord of the special tool to a nearby part. 2. Loosen the nut but do
not remove it.
INSPECTION
Check the lower ball joint end play.
a. Use a dial indicator to measure the lower ball joint end play.
b. If the lower ball joint end play exceeds the service limit, replace the lower ball joint.
INSTALLATION
Installation in reverse order as removal, noting the following:
1. Apply multipurpose grease to the inside of the dust cover and the lower ball joint. 2. Secure the
dust cover to the lower ball join with a ring.
Front wheel alignment adjustment.

Locations

SENSOR VIEW
Page 1861
Thermostat: Description and Operation
Identification Mark ...............................................................................................................................
............................................. 82 Stamped On Flange Type ................................................................
.................................................................................................................................. Wax With Jiggle
Valve
Locations
Directional Sensor: Locations

Page 4589
Speedometer Gear: Service and Repair
DISASSEMBLY
ASSEMBLY
A. Spring pin installation. (1)
1. Drive the spring pin into position so that its slit faces the direction shown in the illustration.
Page 853
Page 4523
Page 2171

EGR Vacuum Line: Testing and Inspection
This article has been updated per manufacturer's TSB #06-13-012
EGR Port Vacuum Check
1. Disconnect the vacuum hose from the throttle body EGR vacuum nipple and connect a hand
vacuum pump to the nipple.
3. Measure engine vacuum at 2500 r/min.
Standard value: 51 kPa (15 in. Hg) or more

Page 2190

Wheel Fastener Torque
Wheel Fastener: Specifications Wheel Fastener Torque
Wheel Nut ............................................................................................................................................

.......................... 98 - 118 Nm (72 - 87 ft. lbs.)
Page 2701

Page 400

Page 7169
motor to the square hole in the drum.
Note:
^ For regulator motor and regulator phase alignment, slide the glass bracket (glass mount) to a
distance of 12.7mm or rotate the drum with a ratchet wrench handle to achieve the same
movement of the bracket.
^ Rotation of the drum may cause the wire to come off the drum. To prevent this, hold the drum
and guide with your hands.
4. Align the guide and the motor housing opening. While holding the guide and the drum, let it slide
into the motor housing.
Note:
To prevent drum runout, bend the lugs so the metallic cover is not loose. If the drum has runout,
the glass may not lower or lift smoothly (example: may rattle when lowering).
5. Align the metallic cover lug with the metallic cover mounting hole. Be sure to bend the lugs to
secure the cover to the housing.
Note:
When replacing the regulator assembly (service part), use a new metallic cover that is in the set.
When replacing only the motor, reuse the removed metallic cover.
6. Apply battery voltage to the power window motor to make sure the glass bracket moves
smoothly.
DRUM AND REGULATOR WIRE ASSEMBLY

Page 1982

Page 4812
Brake Warning Indicator: Electrical Diagrams

Page 1066
Coolant: Fluid Type Specifications
Coolant Type High quality ethylene glycol base anti-freeze/coolant
Mitsubishi Part No. 0103044 (DIA-QUEEN LONG-LIFE COOLANT)
Coolant Conentration 40 - 50 %
Page 2819

Page 122
reprogramming.
Page 5429
has been adjusted.


Page 483
connected.)
connector.
increased.
Page 797
OPERATION
ground.
Page 4414
CONTROL UNIT VIEW

Page 2998
Torque 1.5 ft.lb

Page 1537
Wire Color Codes
the marking color.

Page 510
on actual vehicles.
Wire Color Codes
Page 1035
Drive Belt: Testing and Inspection Power Steering
DRIVE BELT TENSION
1. Measure the flexion of the V belt when it is subjected to a force of 98 N (22 lbs.) in the place
shown.
Standard value:
When checked: 13.8 - 1 7.8 mm (.54 - .70 inch) When an old belt is installed: 14.8- 16.8 mm
(.58-.66 inch) When a new belt is installed: 10.7- 13.7 mm (.42-.54 inch)
2. If the flexion value is outside the standard value, adjust by the following procedure.
a. Loosen tension pulley fixing nut. b. Tighten the fixing nut to the following torque.
Tightening torque: 9.8 - 19.6 Nm (7 - 14 ft.lbs.)
c. Adjusting belt tension with adjusting bolt. d. Tighten the fixing bolt.
Page 6002
Chart E-2
Motor antenna extends and retracts but does not receive.

Page 2866
SENSOR VIEW

Specifications
Lock Up Solenoid ................................................................................................................................

............................................................................................................. 10 Nm (86.4 inch lbs.) Shift
Solenoid No. 2 .....................................................................................................................................
............................ 10 Nm (86.4 inch lbs.)
Page 3807
1996 Montero Service Manual, Volume 1, Page 23C-58 Change the forward clutch piston stroke
specifications as shown.
Page 6342
1997 Montero Service Manual, Volume 2, Page 190 Correct the connector number for D-29 as
shown:
Page 4611
INSPECTION
the ground.
Specifications
Sensor Bolt
Torque 7 ft.lb
Page 3933
C. Thrust race / thrust bearing installation. (3 & 4)

Instruments - Odometer Reset After Replacing
Speedometer
Odometer: Technical Service Bulletins Instruments - Odometer Reset After Replacing

Speedometer
NO.: TSB-06-54-011
DATE: December, 2006
MODEL: All except Raider

SUBJECT: SPEEDOMETER REPLACEMENT & ODOMETER RESETTING TO ACTUAL
MILEAGE
This bulletin supercedes TSB-01-54-006, to update SPECMO's address. Revisions and indicated
by <.
PURPOSE
This bulletin contains instructions for having the odometer on a newly replaced speedometer reset
to the actual vehicle mileage.
AFFECTED VEHICLES All except Raider
PROCEDURE
To administer this program, contact Specmo Enterprises, Inc. Contact information is shown. Ship
the new speedometer head/cluster along with the speedometer being replaced to Specmo at the
address listed. You must include the old speedometer so Specmo's repair facility can verify the
actual recorded mileage. The repair facility will reset the new speedometer's odometer to the actual
mileage indicated. Specmo will return BOTH units to your dealership via overnight shipment.
NOTE:
Retain the old speedometer head/cluster for the normal parts retention period.
PARTS INFORMATION
Diagrams
Page 4873
CAUTION: -
Protect the caliper body with a cloth, and then blow compressed air through the brake hose to
remove the piston boot and the piston.
- Blow compressed air gently.
DOT 4 brake fluid.
Page 1715
injection.
CAUTION: -
100 kPa (14 psi).
NOTE: -
Page 3101
Wire Color Codes
the marking color.

Check
Page 7122


Carpet: Recalls Recall - Rear Cargo Mat
NO: SR-98-004
DATE: October, 1998
PURPOSE
Remedy
area mat
NOTE:
Page 2097

Page 5281
has been adjusted.

Page 2873

Page 735
Grounding Markings

Specifications
Brake Warning Indicator: Specifications
Brake warning light ..............................................................................................................................
...................................................................... 1.12 W
Page 5017
selector lever.
Locations

Page 4822
CAUTION: -
When removing the pistons, be sure to use the handle of a plastic hammer and adjust the height of
the two pistons while pumping in air slowly in so that the pistons protrude evenly.
- Do not remove one piston completely before trying to remove the other piston because it will
become impossible to remove the second piston.
Page 2510
Grounding Markings

Page 1010
Spark Plugs

Limit : 1.3 mm (0.051 in.)
a plug cleaner and
Spark Plug Cable


relay.
AFFECTED VEHICLES
1997-99 Montero

Page 3538
Ignition Coil: Oscilloscope Patterns and Waveforms
Measurement method
parts.
power transistor.

Page 574
Page 4867
Brake Caliper: Testing and Inspection
1. Tighten the disc/rotor to the hub with hub nuts. Measure hub torque (A) with the pads removed
using a spring balance. 2. Securely attach the pads and clips to the caliper support.
3. Clean the piston and insert into cylinder with disc brake piston expander tool No. MB990520. Be
careful that the piston boot does not become
caught, when lowering the caliper assembly and installing the lock pin.
4. Check the brake drag force (B) as follows. 5. Start the engine and hold the brake pedal down for
5 seconds. The pedal depression force should be approximately 196 N (44 pounds.) 6. Stop the
engine. 7. Turn the brake disc forward 10 times.
Check Hub Torque
8. Check the hub torque (B) with a spring scale. Calculate the drag force of the disc brake, the
difference between hub torque (B) and hub torque (A).
The standard value is 69 N (16 pounds) or less.
9. If the brake drag force exceeds the standard value, disassemble and clean the piston. Check for
corrosion or worn piston seal, and check the sliding
condition of the lock pin and Guide pin.

Page 3583
Removal
Installation
Page 6618

Page 1749
Fan Clutch: Description and Operation
Fan Clutch Type
.....................................................................................................................................................
Thermo Type With Spiral Type Bimetal
Page 5226
Centralized Relay
Specifications
At 20° C (68° F) ...................................................................................................................................

................................................... 36 - 46 ohms
Service and Repair
Fluid Line/Hose: Service and Repair

REMOVAL
1. Remove under cover and under skid plate. 2. Drain automatic transmission fluid. 3. Follow
removal steps outlined in illustration.
INSPECTION
1. Check the hose and pipe for crack, damage and clogging. 2. Check for rusted or clogged
radiator oil cooler. 3. Check the fluid cooler fins for bends, damage or foreign materials.
INSTALLATION

Page 507
Grounding Markings

Page 2159

Page 3240
Wire Color Codes
the marking color.

Headliner - Loose/Sagging
Headliner: All Technical Service Bulletins Headliner - Loose/Sagging
NO.: TSB-97-52A-002 DATE: April, 1997 MODEL: 1992-97 Montero
SUBJECT: HEADLINER COMING LOOSE AND SAGGING
PURPOSE This bulletin contains procedures for repairing Montero rear headliners that come loose
and sag.
CAUSE AND REMEDY The rear headliner comes loose in the area where it attaches to the front
headliner because of insufficient attachment force. This condition can be repaired by drilling three
holes in the front and rear headliners and attaching the headliners together with three additional
clips.
REPAIR PROCEDURES
1. Remove the rear headliner. Removal procedures are in section 52A of the service manual.
2. Drill three 6.9 mm holes in the rear headliner at the locations indicated in the illustration.
3. Drill three 15 mm holes in the front headliner at the indicated locations.
4. Reinstall the rear headliner. Attach the rear headliner to the front headliner using the clips listed
in the Parts Information section of this bulletin.
PARTS INFORMATION
Page 6625
Page 4276
Locations
Auxiliary Power Outlet: Locations

Page 3075


Page 1421
NOTE (1)
Page 2999

SENSOR VIEW

Page 1184
Grounding Markings

Page 5839
driver injury.
Page 6165
Exterior Moulding / Trim: Service and Repair
INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS
SIDE GARNISH AND OVER FENDER
REMOVAL OF SIDE GARNISH AND OVER FENDER
1. Apply protective tape to the outside of each side garnish.

Wheel Speed Sensor
Page 3437
Grounding Markings

Page 7069

Page 5229
Centralized Relay
Specifications
Operating Pressure

Page 5612
Tires: Component Tests and General Diagnostics
Tire Inflation Pressure Check
Check the inflation pressure of the tires. If it is not within the standard value, adjust it.
NOTE: Refer to the inflation pressure label on the driver's side.
Tire Wear Check
1. Measure the tread depth of tires.
2. If the remaining tread depth is less than the limit, replace the tire.
NOTE: When the tread depth of tires is reduced to 1.6 mm (.06 inch) or less, wear indicators will
appear.
Page 1633
Crankshaft Main Bearing Seal: Service and Repair With Manual Transmission/Transaxle
1. Remove the transmission. 2. Refer to the illustration for the service procedure, noting the
following:
3. Use the flywheel stopper tool No. MD998781, or equivalent, to secure the flywheel assembly,
and remove the bolts. 4. Cut out a portion in the camshaft oil seal lip.
Page 5859
1997 Montero Sport, Volume 2, page 52B-5, and 1997 Montero Sport Technical Information
Manual, page 6-13
Page 4420

Page 3269
on actual vehicles.
Wire Color Codes
Page 2958
Wire Color Codes
the marking color.

Page 6855
on actual vehicles.
Wire Color Codes
Page 834

CAUTION:
Removal Steps
Reserve tank
work.
Page 2521
increased.

Specifications
Center Mounted Brake Lamp: Specifications
High-mounted stop light 4 bulbs type W 5 W
3 bulbs type cp 21 (921) W

Page 115
check mark button.
VCI COMPONENTS
Page 3114

Locations

Specifications

Specifications
Valve Cover: Specifications
Mounting Bolts .....................................................................................................................................

............................................. 3.5 Nm (2.5 ft. lbs.)
Output Voltage
Voltage 0.6 - 1.0 V

Page 3013
harnesses.
Page 7172
Refer to CAPS or the parts catalog microfiche for power window motor and regulator part numbers.
Standard warranty procedures and policies apply. The Labor Operation Time Schedule (LOTS)
manual has the correct labor operation number and time information for each model covered by
this bulletin. Refer to the LOTS manual when replacing a power window motor an/or regulator on a
vehicle which is still within the warranty period.

INSPECTION
Using Scan Tool
HARNESS INSPECTION
NOTE:
Page 3421
Throttle Body: Service and Repair Throttle Valve Area Cleaning
1. Start the engine and warm it up until the temperature of the engine coolant reaches 80°C
(176°F) or higher; then stop the engine. 2. Disconnect the air intake hose at the throttle body side.
3. Plug the bypass intake port inlet (arrow) into the throttle body.
CAUTION: Never let cleaning liquid get into the bypass intake.
4. Spray cleaning liquid from the intake port of the throttle body onto the valve, and then leave as is
for about five minutes. 5. Start the engine and race it a few times; then let it run at idle speed for
about one minute.
NOTE: The engine idling speed is unstable (or the engine stalls), let the engine run with the throttle
valve slightly open.
6. If deposits are not removed from the throttle valve, repeat steps (4) and (5). 7. Remove the plug
from the bypass intake port inlet in the throttle body. 8. Connect the air intake hose. 9. Using the
scan tool erase the diagnostic trouble code or disconnect the negative battery cable for more than
10 seconds and then connect it again.
10. Adjust the basic idle speed.
NOTE: If hunting of the idling engine occurs after adjusting the basic idling speed, disconnect the
negative battery cable from the battery terminal for more than 10 seconds, and then idle the engine
again.
Page 758
Page 4287
A. Dust seal installation. (5)
Use the special tools to press-fit the new dust seal into the housing tube until it is flush with the
housing tube end face.
B. Dust cover installation. (3)
Use a steel pipe to press-fit a new dust cover onto the inner shaft.
Steel pipe:
Overall length: 50 mm (1.7 inch) Outer diameter: 75 mm (3.0 inch) Wall thickness: 4 mm (0.2 inch)
C. Bearing installation. (2)
Use the special tool to press-fit the bearing onto the inner shaft.
Page 4785
Wheel Speed Sensor: Testing and Inspection Toothed Ring
Check whether the rotor teeth are broken or deformed, and, if so, replace the rotor.
Specifications

Page 2644
Wire Color Codes
the marking color.

Page 508

Page 3723
Wire Color Codes
the marking color.

Page 4227

Page 2953

Page 5453
the vehicle.
A: 1 - 2 mm (.04 - .08 inch) B: 1.5 - 2.5 mm (.06 - .10 inch)
c. Operational steps after installation as follows:
1. Front wheel alignment inspection and adjustment. 2. Bleed brake line.

General Inspection
Power Steering Pump: Testing and Inspection General Inspection
1. Check the drive-belt for cracks. 2. Check the pulley assembly for uneven rotation. 3. Check the
flow control valve for clogging. 4. Check the pulley assembly for wear or damage. 5. Check the
shaft for wear or damage. 6. Check the groove of rotor and vane for "stepped" wear. 7. Check the
contact surface of cam ring and vanes for "stepped" wear. 8. Check the vanes for damage.
9. Check gap between vane and rotor groove.

Page 5816
Page 6836
on actual vehicles.
Wire Color Codes
Page 264
RELAY VIEW
Defogger Relay H
Page 3081
Canister Purge Solenoid: Description and Operation California
OPERATION
- The evaporative emission purge solenoid is an duty control type of solenoid; it functions to
regulate the introduction of purge air from the evaporative emission canister to the intake manifold
plenum.
- Battery positive voltage is supplied, by way of the MFI relay, to the evaporative emission purge
solenoid. When the engine control module switches on the ignition power transistor within the unit,
current flows to the coil, and purge air is introduced.
Page 221
Part 3 Of 3
Page 7030
on actual vehicles.
Wire Color Codes
Page 6196
operation.
rear wheel housing.
c. Tighten bolt A.
d. Tighten bolt B.
f. Tighten bolts C.
PARTS INFORMATION

Page 2018
Grounding Markings

Page 5487
LATERAL ROD BUSHING
Replacement
1. Use the special tool to drive out and press in the lateral rod bushing. 2. Be careful that the
difference (A - B) in bushing projection distances does not exceed the following value.
A - B = 0 ± 1.0 mm (0 ± .04 inch)
CAUTION: When pressing in the bushing, apply a sufficient amount of liquid soap to the inside of
the lateral rod eyes and the rubber area of the bushing.
Page 144

Suspension Strut / Shock Absorber: Diagram Information and Instructions
..................................................................................................................................... 145 ± 14.5
ground ..............................................................................................................................................
246 ± 24.6 Ohm
Page 334


Page 1974
examples 1 and 2.)
low.

Page 2902
Wire Color Codes
the marking color.

Page 893

Page 6646
Wire Color Codes
the marking color.

Page 1862
Thermostat: Testing and Inspection
- Check that valve closes tightly at room temperature.
- Check for defects or damage.
- Check for rust or encrustation on valve. Remove if any. Immerse thermostat in container of water.
Stir to raise water temperature and check that thermostat valve opening temperature and the
temperature with valve fully open [valve lift-over 9 mm (0.35 inch)] are at the standard value.
Standard value:
Valve opening temperature 82° C (180° F) Fully open 95° C (203° F)
NOTE: Measure valve height when fully closed. Calculate lift by measuring the height when fully
open.
Page 428
Page 495
Wire Color Codes
the marking color.

Page 6699
Grounding Markings

Service and Repair
Power Steering Line/Hose: Service and Repair
REMOVAL
INSTALLATION
NOTE: Installation service points as follows: a. Pressure pipe/pressure hose installation (2 & 4).
1. Install so that the pressure pipe and pressure hose mating marks are aligned.
Specifications
Page 4067


Page 6860
Page 5879
! WARNING
^ Do not inhale the smoke produced when the air bag is deployed.
^ The air bag module will be quite hot after deployment. To avoid personal injury, do not handle for
at least 30 minutes.
11. If the air bag module does not deploy after properly following these procedures, do not go near
the module. Contact your regional Tech Line for instructions.
DISPOSAL PROCEDURE
After deployment, dispose of the air bag module as follows:
1. Allow the unit to cool for at least 30 minutes.
2. Do not allow water or oil to contact the air bag after deployment.
! WARNING
Wear safety glasses and heavy gloves when handling the air bag module. If residue material gets
into your eyes or on your skin, immediately rinse the affected area with large quantities of clean
water. If any irritation develops, seek medical attention immediately.
3. Tightly seal the air bag module in a strong vinyl bag.
4. Wash your hands thoroughly after handling the air bag module.
IMPORTANT:
Dispose of the air bag module immediately. Consult your dealership's legal counsel for Federal,
state, and local laws or regulations pertaining to proper disposal of the air bag module.
PARTS INFORMATION
Description Part Number
Driver Side SRS air bag adapter harness MR203491
Passenger Side SRS air bag adapter harness MB686560

Normal warranty replaced parts storage and retention policies apply. Do not dispose of any
replaced air bag or related parts until after the normal holding period or until a "Scrap Now" notice
appears on your statement.
Revisions

numbering.

Page 655
the standard value.

the system.
Page 3459
on actual vehicles.
Wire Color Codes
Page 5266
OPERATION
high to low.
Page 1726
Water Pump: Description and Operation
Water Pump Type ................................................................................................................................
......................................... Centrifugal Type Impeller
Page 2816
SENSOR VIEW

Page 1220
BEARING REPLACEMENT
Page 2578
Wire Color Codes
the marking color.

Page 2226
SENSOR VIEW

Key Cylinder Lamp: Diagram Information and Instructions
Page 3691
COMPONENT VIEW

Page 1032
Page 6355

Page 2807
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Specifications
...................................................................... 1.12 W
Page 1022
Timing Belt: Service and Repair
REPLACEMENT
1. Refer to the illustration for the service procedure.
2. Mark the belt running direction for reference in reinstallation.
NOTE:
4.
Audible Warning Device: Diagram Information and Instructions
Page 697
Page 6647
Oil Pressure Gauge: Electrical Diagrams
Multi Meter
Specifications

............................................ 15 Nm (11 ft. lbs.)
Page 4263
Grounding Markings

Page 5349
Wire Color Codes
the marking color.

Page 2014

SENSOR VIEW

Page 6349
1999 Montero Service Manual, Volume 2, Page 90-137 Add connector 1 as shown and replace the
crossed-out circuit diagram with the new diagram on the next page of this bulletin:
Page 3238


Page 3452

SENSOR VIEW

Page 4506

Inspection
Cigarette Lighter: Testing and Inspection Inspection
Inspection
- Take out the plug, and check for a worn edge on the element spot connection, and for shreds of
tobacco or other material on the element.
- Use an ohmmeter to check for continuity in the element.

Seat Belt Reminder Lamp: Diagram Information and Instructions
Page 2759

Page 4503


Page 2290
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A1 - 92)
control module. -
Page 2193


Refrigerant Leak Repair
Refrigerant: Service and Repair Refrigerant Leak Repair
Lost Charge
If the system has lost all charge due to a leak: 1. Evacuate the system. (Refer to the evacuation
procedure.) 2. Charge the system with approximately one pound of refrigerant. 3. Check for leaks.
4. Discharge the system. 5. Repair the leaks. 6. Replace the receiver drier.
CAUTION: Replacement filter-drier units must be sealed while in storage. The drier used in these
units will saturate water quickly upon exposure to the atmosphere. When installing a drier, have all
tools and supplies ready for quick reassembly to avoid keeping the system open any longer than
necessary.
7. Evacuate and charge the system.
Low Charge
If the system has not lost all of its refrigerant charge, locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak (because of an especially low charge), add
refrigerant. If it is possible to repair the leak without discharging the refrigerant system, use the
procedure for correcting the low refrigerant level.
Page 5709
Component View
Page 2258
- Example 2
normal.
Page 616

Page 6869


Marker Lamp: Diagram Information and Instructions
Cranking Signal: Diagram Information and Instructions
Page 6092
Radio And Tape Player (Part 1 Of 3) (Vehicles Without Amplifier)
Locations

SENSOR VIEW
Page 1554
Grounding Markings

Page 1230
DISASSEMBLY
disc, if necessary.
BEARING REPLACEMENT
Service and Repair
Removal
Installation

Page 3357
Page 915
Page 114
Components

Procedure
DVD-ROM drive.
Page 2745
on actual vehicles.
Wire Color Codes
Page 4166
NOTE: Remove the cover and gasket. Hold the working base in a vise, and install the differential
carrier assembly to it.
Final Drive Gear Backlash
Check the final drive gear backlash by the following procedure: 1. With the drive pinion locked in
place, use a dial indicator to measure the final drive gear backlash on the drive gear.
2. If the backlash is outside the standard value, adjust it by using the side bearing adjustment
spacers.
Drive Gear Runout
Check the drive gear runout by the following procedure: 1. Measure the drive gear runout at the
shoulder on the reverse side of the drive gear.
Limit: 0.05 mm (0.0020 inch)
2. If the runout exceeds the limit, check for incorrect tightening of the drive gear and differential
case.
Differential Gear Backlash
Check the differential gear backlash by the following procedure: 1. While locking the side gear with
a wedge, use a dial indicator to measure the differential gear backlash on the pinion gear.
Page 3982
Page 670
pushed.

malfunction.
Page 3956
Page 3276
Fuel Supply Line: Service and Repair

Page 6716

on actual vehicles.
Wire Color Codes

Basic Idle Speed
readjustment.
procedure.
grounded.

Page 6944
RELAY VIEW
Headlight Relay B
Page 6480
Brake Warning Indicator: Description and Operation
the engine has started. This warning light illuminates when the parking brake is applied or when the
brake fluid level falls to less than the specified level.
Page 194
CONTROL UNIT VIEW
Page 5401
Page 2729
OPERATION
Page 3726
Ignition switch-ST
HARNESS INSPECTION
module. -
NOTE: -

Locations
Name Symbol
Fusible Links 1-7 A
Page 2439
Grounding Markings

Specifications
Torque 7 ft.lb
Page 2324


Page 3712

Page 1327
Document Added Per Manufacturer TSB #08-11-002

Specifications
Flywheel: Specifications
Mounting Bolts .....................................................................................................................................

................................ 72 - 76 Nm (53 - 56 ft. lbs.)
Page 3020
Page 2760


Page 1643
Page 1175

California
Catalytic Converter: Service and Repair California

Page 4621
are matched.
Page 653
OPERATION
high to low.
Specifications
Torsion Bar: Specifications
Length X O.D.: 1307.5 x 26.4 mm (51.476 x 1.039 inch)
Spring Constant (Wheel Position)

....................................................................................................................................... 25 N per mm
(140 lbs. per inch)
Adjustments
Fuel Door: Adjustments
FUEL FILLER DOOR
ADJUSTMENT OF FUEL FILLER DOOR FIT
Loosen the fuel filler door mounting screw and adjust so that the clearance is equal on all side and
the door is flush with the body.
Specifications

............................................ 15 Nm (11 ft. lbs.)
Starter Solenoid: Testing and Inspection
Magnetic Switch Pull-In Test
Magnetic Switch Pull-in Test
1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12 V battery between
S-terminal and M-terminal. 3. Manually pull out the pinion as far as the pinion stopper position.
CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent coil from
burning.
4. If pinion moves out, then pull-in coil is good. If it doesn't, replace magnetic switch.
Magnetic Switch Hold-In Test
Magnetic Switch Hold-in Test
S-terminal and body.
burning.
3. If pinion remains out, everything is in order. If pinion moves in, hold-in circuit is open. Replace
magnetic switch.
Fig. 9 Testing Magnetic Switch Return Function
Magnetic Switch Return Test
M-terminal and body.
burning.
3. Pull pinion out and release. If pinion quickly returns to its original position, everything is in order.
If it doesn't, replace magnetic switch.
Page 6450
ABS Light: Testing and Inspection
Check that the ABS warning light illuminates as follows.
1. When the ignition key is turned to "ON," the ABS warning light illuminates for approximately 1
second and then switches "OFF." 2. When the ignition key is turned to "START," the ABS warning
light remains illuminated. 3. When the ignition key is released from the "START" position, the ABS
warning light illuminates for approximately 1 second and then stays
switched "OFF."
4. If the illumination is other than the above, check the Diagnostic Trouble Codes (DTC). See:
Brakes and Traction Control/Antilock Brakes /
Traction Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview

Page 5808
Page 1763

SENSOR VIEW

Page 5163

Fuel Gauge Type
Fuel Gauge: Specifications Fuel Gauge Type
Fuel Gauge is a Cross Coil type gauge.
Page 4015
INSTALLATION
the cable band.
Page 1849
activated.
Page 3111
EGR Control Solenoid: Locations
COMPONENT VIEW
EGR Solenoid D
Page 135
on actual vehicles.
Wire Color Codes
Page 2502
Cranking Signal: Testing and Inspection
INSPECTION
Using Scan Tool
HARNESS INSPECTION
STEP 1. Measure the engine control module input voltage. -
- Ignition switch: START Voltage (V): 8 or higher OK: GO TO STEP 2 NG: Repair the harness. (71
- Ignition switch)

Engine control module connector: Disconnected OK: STOP NG: Repair the harness. (91 - Ground)
Vacuum Control Flap Switchover Valve: Testing and Inspection
1. Disconnect the vacuum hose (white stripe) from the vacuum control valve and connect the hand
vacuum pump to the vacuum control valve. 2. Put the blind plug to the removed vacuum hose. 3.
Start the engine and run at idle.
4. Check the vacuum condition.

Fluid - Differential: Capacity Specifications
Front Axle ............................................................................................................................................
...................................................................... 1.22 qts.
Rear Axle .............................................................................................................................................

....................................................................... 3.3 qts.
Page 1501
Oil Cooler: Testing and Inspection
OIL COOLER
1. Check for foreign material between the oil cooler fins. 2. Check the oil cooler fins for bends or
damage. 3. Check the oil cooler pipes for cracks, damage, clogging or deterioration.
OIL COOLER BYPASS VALVE
1. Make sure that the valve moves smoothly. 2. Ensure that the dimension L measures the
standard value under normal temperature and humidity.
Dimension L: 34.5 mm (1.358 inch)
3. The dimension must be the standard value when measured after the valve has been dipped in
100° C (212° F) oil.
Dimension L: 40 mm (1.57 inch) or more

Page 6832

Vehicles With Limited Slip Differential
Page 5022
RELAY VIEW
Generator Relay B
Page 2443
Wire Color Codes
the marking color.

Rear 1300-1500 ohms

Page 6692

Page 1860
Page 3086
HARNESS INSPECTION
STEP 1. Check for continuity between the evaporative emission purge solenoid and the MFI relay.
-
Evaporative emission purge solenoid connector: Disconnected

NOTE: -
OK: GO TO STEP 2 NG: Repair the harness. (A1 - C1)
STEP 2. Check for an open circuit or a short-circuit to ground between the evaporative emission
purge solenoid and the engine control module. -
Fuel Injector: Component Tests and General Diagnostics
Hint 1: If there is a problem with starting while the engine is warm, perform the combustion test and
check for leakage of the injectors. Hint 2: If the engine can't be started and the injectors are not
activated during cranking, the cause is probably a malfunction such as described below, not a
problem with the injectors. (1) Malfunction of power supply circuit or ground circuit of engine control
module (2) Malfunction of MFI relay (3) Malfunction of crankshaft position sensor and/or camshaft
position sensor Hint 3: If there is a cylinder for which the idling condition does not change when,
during idling, the fuel injection of the injectors is cut off in sequence, check that cylinder as
described below. (1) Check the injector and harness. (2) Check the spark plugs and the
high-tension cable. (3) Check the compression pressure. Hint 4: If the injector activation time is
outside the standard value even though the results of the checking of the injector's harness and of
the injector itself are normal, the cause is probably one of the following. (1) Incomplete combustion
inside a cylinder
(Malfunction of spark plugs, ignition coil, compression pressure, etc.)

(2) Increased engine resistance

Page 6272
Wire Color Codes
the marking color.

Page 5455
CAUTION: 1. Be sure to tie the cord of the special tool to a nearby part. 2. Loosen the nut but do
not remove it.
INSPECTION
1. Check the lower ball joint end play.
a. Use a dial indicator to measure the lower ball joint end play.
b. If the lower ball joint end play exceeds the service limit, replace the lower ball joint.
INSTALLATION
Front wheel alignment adjustment.

Page 1208
Tires: Application and ID
GENERAL INFORMATION
A full size spare tire has been adopted as the spare tire in all models.
Tire
Size: 265/7OR15 110H.

Page 7215

Page 3550
examples 1 and 2.)
low.

Page 1614
on actual vehicles.
Wire Color Codes
Page 4497
COMPONENT VIEW

Page 587


NO.: TSB-95-16-003
MODEL: All Models
VEHICLES AFFECTED
All models
PROCEDURE
CAUTION:

Page 3102
Page 2887
HARNESS INSPECTION
NOTE: -

Specifications
Valve Guide: Specifications
DIMENSIONS
Clearance Between Valve Guide And Valve Stem
Intake:
Standard Value
.......................................................................................................................................... 0.02 - 0.05
mm (0.0008 - 0.0020 inch) Limit ..........................................................................................................
.......................................................................... 0.10 mm (0.004 inch)
Exhaust:
Standard Value
.......................................................................................................................................... 0.04 - 0.07
mm (0.0016 - 0.0028 inch) Limit ..........................................................................................................
.......................................................................... 0.15 mm (0.006 inch)
Guide Hole Diameters (I/E):
0.05 O.S.
.....................................................................................................................................................
11.05 - 11.07 mm (0.4350 - 0.4358 inch) 0.25 O.S.
.....................................................................................................................................................
11.25 - 11.32 mm (0.4429 - 0.4457 inch) 0.50 O.S.
.....................................................................................................................................................
11.50 - 11.52 mm (0.4528 - 0.4535 inch)
Inner Diameter .....................................................................................................................................

.............................................. 6.0 mm (0.315 inch) Outer Diameter ....................................................
............................................................................................................................ 11.0 mm (0.433
inch)
Page 7221
RELAY VIEW

Torque 1.5 ft.lb

Page 811
Grounding Markings

Fluid - Transfer Case: Capacity Specifications
SPECIFIED LUBRICANTS Transfer Oil Quantity
.............................................................................................................................................................
Approximately 2.5 L (2.4 qts.)
Page 4103
Page 604
Wire Color Codes
the marking color.

Page 6348
1999 Montero Service Manual, Volume 2, Page 80-13 Correct the description for D-35 as shown:
Page 6078
Speaker: Service and Repair Front Speaker (RH)
Front Speaker LH - Removal And Installation
Removal
Installation

Page 2475

Resistance/Torque
Design Thermistor

Page 4436

Page 6594

Page 4070
Page 5848
Caution
2. Do not drop the air bag module or clock spring or allow contact with water, grease or oil. Replace
it if a dent, crack, deformation or rust are detected.
3. The air bag modules should be stored on a flat surface and placed so that the pad surface is
facing upward. Do not place anything on top of the air bag modules.
4. Do not expose the air bag module to temperatures over 93°C (200°F).
5. After deployment of an air bag, replace the air bag modules. Check the clock spring. If faulty,
replace it with a new part.
6. Wear gloves and safety glasses when handling an air bag that has deployed.
7. An undeployed air bag module should only be disposed of in accordance with the procedures
specified under "Undeployed Air Bag Module Disposal" in this manual section.
1997 3000GT, volume 1, page 52B-4

Page 2574
Grounding Markings

Page 1768

Page 2487
INSPECTION
Using Scan Tool
HARNESS INSPECTION
harness. (A2 - 92)
(A1 - 83)

Page 5787
Page 5299
Idler Arm: Service and Repair
STEERING LINKAGE
REMOVAL

Page 1144
Teck Line.
Page 5647
Air Duct: Service and Repair Ventilators (Instrument Panel and Floor)
Page 338
OPERATION
engine is cold.
Page 1911
Download Error

Page 5391
ASSEMBLY
Page 3466
harnesses.
Page 4459
Page 4925
- Install the adjuster so that the shoe adjusting bolt for the left-hand wheel is towards the rear of the
vehicle, and the shoe adjusting bolt for the right-hand wheel is towards the front of the vehicle.
Page 6988
License Plate Lamp: Description and Operation
Locations

Brake Warning Indicator: Diagram Information and Instructions
Page 3326

Page 2103
increases.
INSPECTION
Using Scan Tool
HARNESS INSPECTION
- 92)
(A6 - 72)
Page 6719
Page 1596

Page 4178
4. Use a dial indicator to measure the differential gear backlash on the pinion gear.
Standard value: 0.076 mm (0.0030 inch) or less Limit: 0.2 mm (0.0079 inch)
If the differential gear backlash exceeds the limit, adjust the backlash by installing thicker side gear
thrust spacers.
6. Measure the differential gear backlash again, and check that it is within the limit. If adjustment is
not possible, replace the side gears and
pinion gears as a set.
F. Lock pin installation. (24)
1. Align the pinion shaft lock pin hole with the differential case lock pin hole, and then drive in the
lock pin. 2. Stake the lock pin with a punch at two points.
G. Drive gear installation. (25)
1. Clean the drive gear mounting bolts.
2. Remove the adhesive which is adhering to the threaded holes of the drive gear by turning the
tap tool (tap M10 x 1.25), and then clean the
threaded holes by applying compressed air.
3. Apply specified adhesive to the threaded holes of the drive gear.
Specified adhesive: 3MStud Locking Part No. 4170 or equivalent.
4. Install the drive gear to the differential case so that the mating marks are properly aligned.
Tighten the bolts to the specified torque in a
diagonal sequence.
Page 5911
4. Align the paint mark of the SRS check harness connector No.4 with the notch in clock spring
connector No.2 (arrow in the illustration) to
connect the connectors Nos.2 and 4.
5. Check continuity between the terminals 22 and 23 of the SRS check harness connectors No.5.
Page 1283
NOTE ^
system.

Specifications
Engine Oil Pressure: Specifications
The manufacturer does not provide this specification.
Valve Body Assembly
Valve Body: Service and Repair Valve Body Assembly
Disassembly
Page 2932

Inspection
switch.
Continuity Check
Page 3378
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A2 - 87)
- 92)
Page 3397
position sensor.

Page 2989
Page 4914
- When installing the anchor-to-shoe spring. The load on the respective anchor to shoe springs is
different, so the spring indicated by the arrow has been painted for identification.
- Install the adjuster so that the shoe adjusting bolt for the left-hand wheel is towards the rear of the
vehicle, and the shoe adjusting bolt for the right-hand wheel is towards the front of the vehicle.
Inspection
switch.
Continuity Check
Page 4450
Ignition switch-ST
HARNESS INSPECTION
module. -
NOTE: -

Page 6037
Page 4406

Page 4117
VALVE SPRING
1. Check the free height and outside diameter of each spring.
Assembly
1. Install the plug as illustrated. 2. Install the pin.
3. Install the accumulator control valve and spring to the accumulator control valve sleeve as
illustrated. 4. Install the accumulator control valve sleeve, accumulator control valve and spring
together. 5. While pushing the accumulator control valve sleeve with a finger, install the seat. 6.
Install the washer to the primary regulator valve. 7. Install the washer and primary regulator valve
together.
8. Install the primary regulator valve plunger to the pressure regulator valve sleeve as illustrated. 9.
Install the spring, pressure regulator valve sleeve and primary regulator valve plunger together.
Page 1256
Camshaft: Testing and Inspection
1. Inspect the camshaft bearing journals for damage and binding. If the journals are binding, also
check the cylinder head for damage. Also check the
cylinder head oil holes for clogging.
2. Check the tooth surface of the distributor drive gear teeth of the camshaft and replace if
abnormal wear is evident. 3. Check the cam surface for abnormal wear and damage and replace if
defective. Also, measure the cam height and replace if out of limit:
Intake
Standard Value: 37.58 mm (1.48 inch) Limit: 37.08 mm (1.46 inch)
Exhaust
Standard Value: 36.95 mm (1.45 inch) Limit: 36.45 mm (1.44 inch)

Page 6968
Grounding Markings

Page 7133
RELAY VIEW
Defogger Timer J
Page 2186
Torque 1.5 ft.lb

Page 5832
Steering Wheel, Steering Column And Intermediate Joint
1. Check wiring harness (built into steering wheel) and connectors for damage, and terminals for
deformities. 2. Install air bag module to check fit or alignment with steering wheel. 3. Check
steering wheel for noise, binding, difficult operation, or excessive free play.
Harness Connector (body And Front Wiring Harness)
Check for binding harness, connector damage, poor connections, and deformed terminals.
Page 4693

control module.
Page 4241
are matched.
Inspection
switch.
Continuity Check
Page 441
Grounding Markings

Page 2933



Page 4111
12. Remove the strainer from the upper valve body.
13. Check that the one pin, four seats, three keys and one vibrating stopper are all in position.
Assembly
1. Install the solenoid oil strainer to the upper valve body.
2. Install two types of 9 balls to the upper valve body.

Page 6805
Voltage Meter Simple Check

Page 2560

Engine - Pinging Condition
Fuel: All Technical Service Bulletins Engine - Pinging Condition
SOURCE: Mitsubishi Tech Talk Article October 2004
SERVICE TIP:
When diagnosing an engine pinging condition, always check for engine carbon deposits, which
may have occurred due to fuel grade or quality and/or the customer's driving style. If necessary,
clean carbon deposits from the pistons and combustion chamber. Recommend to customers to
always use the correct grade of fuel for their model vehicle.
Page 2577
on actual vehicles.
Wire Color Codes
Page 1469
Drive Belt: Adjustments Power Steering
DRIVE BELT TENSION
shown.
Standard value:
c. Adjusting belt tension with adjusting bolt.

Page 5205
Wire Color Codes
the marking color.

Page 5288
Page 2192

Page 3860
INSPECTION
Forward Clutch Disc
Limit: 1.84 mm (0.0724 inch)
the limit.
Forward Clutch Piston
Forward Clutch Piston Stroke
1. Install the forward clutch to the overdrive support assembly. 2. Using a dial gauge, measure the
piston stroke by applying compressed air (400-800 kPa, 57-113 psi) into the oil hole of the
overdrive support
as shown and then releasing the air.

Page 3132
Federal Models Only

Specifications
Operating Pressure

Page 7214
RELAY VIEW

Specifications
Firing Order .........................................................................................................................................

............................................................. 1-2-3-4-5-6.
Page 4824
Page 2429
Fuel Gage Resistance Check
Fuel Gauge: Testing and Inspection Fuel Gage Resistance Check
Fuel Gage Resistance Check
Fuel Gage Resistance Check - Chart
Use an ohmmeter to measure the resistance between the terminals.

Page 6087

Page 4507

Specifications
Seat Belt Reminder Lamp: Specifications
Seat Belt Warning Light .......................................................................................................................
...................................................................... 1.12 W
Turn-Signal Light and Hazard Light
Turn Signal Lamp: Testing and Inspection Turn-Signal Light and Hazard Light
1. Neither the turn-signal lights nor hazard lights operate.
- Check the hazard light switch. See: Hazard Warning Lamps/Hazard Warning Switch/Testing and
Inspection
- Check the flasher unit.
2. All L.H. or R.H. turn-signal lights do not illuminate.
a. Hazard light is fully operational.
- Check the turn-signal light switch. See: Turn-Signal Light and Lighting Switch Check
Inspection
3. Flashing cycle of turn-signal lights is shorter.
4. Hazard light does not operate.
a. Turn-signal lights are operational.
Inspection
Page 4995
FRONT REPLACEMENT
Page 2089
INSPECTION
Using Scan Tool
HARNESS INSPECTION
harness (A2 - 92)
- 77)
Page 4996
- Ensure the sensors' output voltage is within specifications. See: Testing and Inspection
- Insert a feeler gage into the space between the speed sensors' pole piece and the rotors' toothed
surface, and check to be sure that the clearance at all points is within the standard value. The
standard value is 0.2-1.0 mm (0.008-0.039 inch.)
NOTE: If the clearance between the speed sensor pole piece and the rotor toothed surface is not
within the standard value range, it is probable that the rotor is incorrectly installed, so re-check
installation.
REAR REPLACEMENT
1. Remove the band. 2. Remove the rear speed sensor.
3. Remove the O-ring and clip. 4. Remove the rear rotor. Refer to "Transmission and Drivetrain." 5.
Reverse procedure to install, ensuring the sensors' output voltage is within specifications. See:
Page 5446
Ball Joint: Specifications Ball Joint Breakaway Torque Check/End Play
Upper Arm
Breakaway Torque ..............................................................................................................................

..................................... 0.8 - 3.5 Nm (7 - 30 inch lbs.)
Lower Arm
Breakaway Torque ..............................................................................................................................

..................................... 0.8 - 3.5 Nm (7 - 30 inch lbs.) End Play Limit ................................................
......................................................................................................................................... 0.3 mm
(.012 inch)
Page 891

Page 3356
Wire Color Codes
the marking color.

Page 617
SENSOR VIEW
Right Bank Heated Oxygen Sensor (front) P
Right Bank Heated Oxygen Sensor (rear) Q

Page 6666
on actual vehicles.
Wire Color Codes
Page 1465
Drive Belt: Testing and Inspection Power Steering
DRIVE BELT TENSION
shown.
Standard value:
c. Adjusting belt tension with adjusting bolt. d. Tighten the fixing bolt.
Page 1040
d. Tighten the fixing bolt.
Page 106
Dedicated Fuse
Page 6837
Wire Color Codes
the marking color.

Page 356
Disconnect the connector of the control switch and operate the control switch to measure the
resistance between the individual terminals.
If the readings are as shown below, the control switch may be considered good.
Page 6545
on actual vehicles.
Wire Color Codes
Page 802
increased.

Page 5312
Power Steering Fluid: Testing and Inspection
FLUID LEVEL CHECK
1. Park the vehicle on a flat, level surface, start the engine, and then turn the steering wheel
several times to raise the temperature of the fluid to
2. With the engine running, turn the wheel all the way to the left and right several times.
3. Check the fluid in the oil reservoir for foaming or milkiness. 4. Check the difference of the fluid
level when the engine is stopped, and while it is running. If the fluid level changes considerably, air
bleeding
should be done.
Page 4728
transfer case.
transfer case.

transfer case.

INSPECTION
Page 7182
1. Place the drum, guide, regulator, etc. on the work bench as shown.
a. Place the drum so the square hole side faces upward.
b. Place the guide with the slits up.
c. Place the regulator with the glass bracket down, and leave the glass in its fully open position.
Note:
Use only one spring (A or B) depending on the model being repaired.
2. Put the wires through the springs. Install the lowering wire to the guide first, then install the lifting
wire. (The lifting wire should be placed over the lowering wire.)
3. Using a wire (about 0.5 mm in diameter) and twisting, compress the spring.
Note:
Bind the wires at a slit portion of the guide.

Page 4466
NOTE:
NOTE:
Page 1030
Drive Belt: Specifications Power Steering
When checked
..............................................................................................................................................................
13.8 - 17.8 mm (0.54 - 0.70 inch) When new belt is installed
............................................................................................................................................ 10.7 -
......................................................................................................................................... 14.8 - 16.8
mm (0.58 - 0.66 inch)
TENSION
When checked .....................................................................................................................................

.................................................................................................................................................... 490 -
...................................................................................................................................................... 343
- 441 N (77 - 99 lbs.)
NOTE: Apply 98 N (22 lbs.) force to the belt back midway between the pulleys, measure the
amount of deflection.
Fixing Nut ............................................................................................................................................

................................. 9.8 - 19.6 Nm (7 - 14 ft.lbs.)
Page 7071
Page 2636
SENSOR VIEW

(Part 1 Of 2)
(Part 2 Of 2)
Page 5559
Grounding Markings

Specifications
Speedometer Gear: Specifications
Speedometer Driven Gear Sleeve Clamp Mounting

Bolt........................................................................................................................19 Nm (14 ft. lbs.)
Page 1201
Use only cable chains that meet SAE "S" clearance specifications.
Page 381
Component View
Page 4846
shown.
Page 7176
RELAY VIEW

Page 4665
Wire Color Codes
the marking color.

Specifications
Torque 7 ft.lb
Page 2801
Wire Color Codes
the marking color.

Page 3694

Page 1112
Lubricant Differences
Mineral oil is used to lubricate the compressor in an R12 system. Since mineral oil is incompatible
with R134a, it cannot be used in an R134a system. Synthetic oil must be used with R134a. There
are different types, and not all of these are compatible. For instance, SUN PAG 56 must not be
intermixed with ND-OIL8. MMSA Refrigerant Oil A993ZC1X03 may not be mixed with MMSA
Refrigerant Oil A9937C1X04. Consult the under-hood label or the A/C Specifications page of the
vehicle service manual for the correct oil for a particular vehicle.
Retrofitting Systems
Mitsubishi Motor Sales of America, Inc. is monitoring the supply of R12 to arrive at an appropriate
point for offering retrofit kits for its 1993 and earlier models. Retrofit kits will vary from vehicle to
vehicle.
It will be necessary to educate customers about retrofitting. Please assure those who think
retrofitting is mandatory that it is not, and advise them that the decision is fundamentally an
economic one. Whether or not to retrofit depends on the relative costs of R12 and R134a (and
these are changing constantly) and the parts and labor involved in retrofitting the customer's car.
Retrofitting a car to use R134a involves evacuating the car's system, recovering the refrigerant,
flushing the system, installing the components, hoses and fittings that make up the retrofit kit, and
recharging the system with R134a.
Recovery and Recycling of Refrigerants
When servicing an A/C system, the refrigerant that is in the system must be drawn from the system
into a storage container. Before this is done, assure yourself that the system is not contaminated.
Find out the vehicle's service history, if possible. If the vehicle has been to several shops to cure a
mysterious A/C problem, be extremely wary. Inspect the service fittings for signs of tampering.
Makeshift or damaged fittings could indicate tampering and possible contamination. If your shop
has a Refrigerant Identifier, such as the one sold by Snap-On, connect the Refrigerant Identifier to
the system. If it identifies a flammable gas, or a mixture of refrigerants, or a refrigerant other than
what the system was designed for, you may want to refuse to service the system. If the Refrigerant
Identifier shows excessive air, the air can be removed from the refrigerant by using a recycling
machine with a non-condensable purge.
The recovery equipment must have shutoff valves within 12" of the hoses' service ends. With
valves closed, connect the hoses to the vehicle's A/C service fittings. Recover the refrigerant,
continuing until the vehicle's system shows a vacuum instead of pressure. Turn off the
recovery/recycling unit for at least five minutes. If the system still has pressure, repeat the recovery
process to remove any remaining refrigerant. Continue until the A/C system holds a stable vacuum
for two minutes. Then close the service equipment valves and disconnect the hoses. Measure the
recovered oil and replace it with the same amount and type.
Storing Recycled Refrigerant
Use only "DOT CFR Title 49" or "UL Approved" containers for recycled refrigerant. The letters are
stamped into the metal of the ring surrounding the valve. Containers specifically made for R134a
refrigerant should be marked accordingly. Never use disposable containers for storing refrigerant.
Transferring Recycled Refrigerant
Use only DOT-approved containers. Evacuate the container to at least 27" Hg before transferring
the refrigerant. Never fill a container to more than 60% of its gross weight rating. For example, a
30-lb. container would take 18 lb. and a 50-lb. container would take 30 lb.
Recycled refrigerant is used refrigerant that has been recovered from customers vehicle A/C
systems by any shop servicing A/C. This same shop may also send recovered refrigerant to a
reclaimer who processes the refrigerant so that it meets purity standards that are higher than those
for recycled refrigerant. This refrigerant is known as reclaimed refrigerant. When buying reclaimed
refrigerant, be sure it meets API 700-88 requirements. The EPA Hotline (1-800-296-1996) can
provide information on approved refrigerant reclaimers.
Before using any container of recycled refrigerant, check for non-condensable gases (air). This can
be done with the Refrigerant Identifier or by the following process:
1. Keep the container at 65°F for at least 12 hours, out of direct sunlight.
2. Connect a pressure gauge calibrated in 1-psi divisions to the container and read the pressure.
3. With an accurate thermometer, measure the air temperature within 4 in. of the container.
4. Compare the pressure in the chart. See if the pressure is at or below the limit shown.
5. If the pressure of the refrigerant is lower than the limit shown for a given temperature, the
refrigerant is OK to use as is.
Page 3043

Page 5754
Receiver Dryer: Testing and Inspection
To Test the Receiver Drier
1. Operate the unit and check the piping temperature by touching the receiver drier outlet and inlet.
2. If there is a difference in the temperatures, the receiver drier is blocked. Replace the receiver
drier.
Page 6718

Page 1124
12. Turn the vacuum pump adaptor switch to the R-134a side to start the vacuum pump.
CAUTION: Do not operate the air conditioning compressor to carry out evacuation.
13. Evacuate to a vacuum reading of 100 kPa (29.5 in.Hg) or higher (takes approx. 10 minutes).
14. Turn the vacuum pump adaptor switch OFF and allow to stand it for 5 minutes.
CAUTION: Do not operate the compressor in the vacuum condition, as damage may occur.
15. Carry out a leak test. (Good if the negative pressure does not drop.)
CAUTION: If the negative pressure is lost, check for loose connections. Then, repeat the
evacuation procedure from step 12. If the negative pressure is still lost, add 1 lb of refrigerant and
then use an R-134a compatible leak detector to check the system.
16. Turn the handle of the adaptor valve back all the way (valve closed), remove it from the gage
manifold and install the bulk container.
17. Open the valve of the bulk container. 18. Turn the handle of the charge valve back (valve open)
and tighten the handle of the adaptor valve (valve open) to charge the system with
refrigerant.
CAUTION: If the bulk container is inverted, liquid refrigerant may be drawn into the compressor,
damaging it by hydraulic lock. Keep the bulk container upright to ensure that refrigerant is charged
in gas state.
19. If the refrigerant is not drawn in, turn the handle of the adaptor valve back all the way (valve
closed). 20. Use a leak detector to check for gas leaks.
If a gas leak is detected, re-tighten the connections and then repeat the charging procedure from
evacuation in step (12).
CAUTION: A leak detector designed for R-134a should be used.

Page 3003
Grounding Markings

Page 6907
Multi Meter
Page 2479

Page 771

Specifications
Brake Master Cylinder: Specifications
DIMENSIONS
Inner Diameter .....................................................................................................................................

............................................. 23.8 mm (0.94 inch)
Flare Nuts/Brake Pipe .........................................................................................................................

................................................. 15 Nm (11 ft. lbs.)
Page 5454
Ball Joint: Service and Repair Lower Ball Joint

REMOVAL
NOTE: Removal service points as follows: a. Lower ball joint and knuckle disconnection (5).
Page 1098
Engine Oil: Service Precautions
WARNING:
PROLONGED AND REPEATED CONTACT WITH MINERAL OIL WILL RESULT IN THE
REMOVAL OF NATURAL FATS FROM THE SKIN, LEADING TO DRYNESS, IRRITATION AND
DERMATITIS. IN ADDITION, USED ENGINE OIL CONTAINS POTENTIALLY HARMFUL
CONTAMINANTS WHICH MAY CAUSE SKIN CANCER. ADEQUATE MEANS OF SKIN
PROTECTION AND WASHING FACILITIES MUST BE PROVIDED.
RECOMMENDED PRECAUTIONS
- The most effective precaution is to adapt working practices which prevent, as far as practicable,
the risk of skin contact with mineral oils. For example; Use enclosed systems for handling used
engine oil and degrease components, where practicable, before handling them.
- Avoid prolonged and repeated contact with oils, particularly used engine oils.
- Wear protective clothing, including impervious gloves where practicable.
- Avoid contaminating clothes, particularly underpants, with oil.
- Do not put oily rags in pockets, the use of overalls without pockets will avoid this.
- Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned
regularly and kept separate from personal clothing.
- Where there is a risk of eye contact, eye protection should be worn. For example; chemical
goggles or face shields. In addition, an eye wash facility should be provided.
- Obtain First Aid treatment immediately for open cuts and wounds.
- Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin
cleansers and nail brushes will help). After cleaning, the application of preparations containing
lanolin to replace the natural skin oils is advised.
- Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin.
- Use barrier creams, applying them before each work period, to help the removal of oil from the
skin after work.
- If skin disorders develop, obtain medical advice immediately.

Page 801
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Page 6380
operation.
rear wheel housing.
c. Tighten bolt A.
d. Tighten bolt B.
f. Tighten bolts C.
PARTS INFORMATION

Page 4702
Page 7054
Page 1338
1. Mark the cylinder number on the side of the connecting rod big end for correct reassembly. 2.
Keep the removed connecting rods, caps, and bearings in order according to the cylinder number.
3. Remove the snap rings from the piston pin.
4. When removing the piston pin, heat the piston to approximately 70° C (158° F) and pull out the
piston pin.
NOTE: -
rod small end.
Page 1154
Dedicated Fuse
Page 5887
Air Bag Module (passenger's Side)
Air Bag Module Removal Steps (Passenger's side)
1. Negative (-) battery cable connection 8. Foot shower duct (R.H) 9. Stopper
10. Glove box 11. Air bag module (Passenger's side)
- Pre-installation inspection
work.
Step 2: Air Bag Module Removal 1. Remove the air bag module mounting nut using a socket
wrench from the back side.
Page 2207

Page 5968
Seat Belt Reminder Lamp: Electrical Diagrams

Locations

Page 4078

Page 590
Page 3576
Page 1462
Page 5376
Key Reminder Switch

Page 1872
Water Pump: Specifications
Mounting Bolt .......................................................................................................................................

............................................... 24 Nm (17 ft. lbs.)
Page 2640
Grounding Markings

Specifications

Page 6457

Locations

Page 4110
6. Remove the check valve and spring from the lower valve body. 7. Remove the pressure relief
valve and spring from the lower valve body.
8. Remove the three strainers from the lower valve body.
9. Check that the three seats, one pin and one clip are in position on the lower valve body.
10. Remove the two valve body gaskets and the plate from the upper valve body.
11. Remove the 9 balls from the upper valve body.

Page 2697

Application and ID
GENERAL INFORMATION

Page 5872
1997 Galant Service Manual, Volume 1, Page 52B-17 Add the new SRS troubleshooting
Page 5873
Radiator: Mechanical Specifications
Mounting Bolts .....................................................................................................................................

.................................................. 10 Nm (7 ft. lbs.)
Coolant: Capacity Specifications
Cooling Capacity 10.0 qt (US)
Including heater and coolant reserve tank.

Page 1336
Page 3225
Fuel Filler Cap: Technical Service Bulletins Fuel/Emissions - Loose Gas Cap/MIL ON
TITLE: Loose Gas Caps and Check Engine Light
SERVICE TIP: A gas cap which is not properly tightened after refueling can cause EVAP DTC's
and check engine light illumination. If you encounter related EVAP DTC's, check the fuel cap first.
Also, very little effort is required on later model vehicles to properly secure the gas cap.
Page 7199

procedures apply.
Page 2770
Removal
Installation
Page 1125
21. Start the engine. 22. Operate the air conditioning and set it to the lowest temperature (MAX.
COOL). 23. Fix the engine speed at 1,500 r/min. 24. Tighten the handle of the adaptor valve (valve
open) to charge the required volume of refrigerant.
in gas state.
25. After charging with refrigerant, turn the handle of the adaptor valve back all the way (valve
closed). 26. Tighten the charge valve handle (valved closed). Disconnect the quick joint (for low
pressure) from the low-pressure service valve.
CORRECTING LOW REFRIGERANT LEVEL WHEN THE BULK CONTAINER IS USED
1. Install the adaptor valve with the handle turned all the way in (valve closed) to the charge valve.
2. Connect the charging hose (blue) to the adaptor valve. 3. Connect the charging hose (blue) to
the quick joint (for low pressure). 4. Open the valve of the bulk container. 5. Turn the handle of the
adaptor valve to bleed the air.
6. Connect the quick joint (for low pressure) to the low pressure service valve.
COOL). 9. Fix the engine speed at 1,500 r/min.
10. Tighten the handle of the adaptor valve (valve open) and replenish refrigerant while checking
the quantity through the sight glass.
CAUTION: If the bulk container is inverted, liquid refrigerant may be draw into the compressor,
in gas state.
11. After replenishing is completed, turn the handle of the adaptor valve all the way in (valve
closed) and disconnect the quick joint.
METHOD USING A REFRIGERANT RECOVERY AND RECYCLING UNIT
Use the refrigerant recovery and recycling unit to refill with refrigerant.
Page 1257
Camshaft: Service and Repair
Refer to the illustration for the service procedures, noting the following points:
1. Install the lash adjuster holder tool No. MD998443, or equivalent, to the rocker arm to hold the
lash adjuster in place.
Page 2057
Grounding Markings

Page 6819
on actual vehicles.
Wire Color Codes
Page 1114
When it becomes necessary to dispose of contaminated refrigerant, the refrigerant should be
stored in a suitable container as described in this bulletin, labeled to identify it clearly, and offered
to a company equipped to handle the container and the contaminated refrigerant. Your dealership
may already have a company to handle its toxic wastes, and perhaps this company can handle the
refrigerant. If a company specializing in refrigerant reclaim is preferred, the EPA Hotline
(1-800-296-1996) can provide a list of approved refrigerant reclaimers.
Page 4667

Page 1401
Piston Pin: Service and Repair
REPLACEMENT
1. Remove the snap rings from the piston pin. 2. When removing the piston pin, heat the piston to
approximately 70° C (158° F) and pull out the piston pin.
NOTE: -
rod small end.

Page 668
Page 6475


Page 5724
7. Shake the bottle of Mitsubishi Cooling Coil Coating well, then attach it to the assembled
applicator kit as shown in the illustration.
8. Close the passenger side air vents. Open the passenger side door. Be sure you are wearing
safety goggles, a face mask (3M: 07185 is recommended), and gloves.
9. With the engine still idling, tan on HI speed, and the mode on recirculate, insert the applicator
nozzle in through the recirculate door opening (or on late model Galant and Eclipse with HVAC
filter, through the filter opening). Spray the coating product in short bursts, with a few seconds
between each burst.
NOTE:
This procedure wets the entire air entry passage and may create a fog from the air outlet vents
which will enter the passenger compartment. This will NOT stain or harm the vehicle's interior.
Be sure to use to use goggles and breathing protection (3M: 07185). DO NOT inhale vapors.
10. When the coating product bottle is empty, shut oft the vehicle's ignition switch. Let the vehicle
sit for 30 minutes. This allows the liquid to flow over the evaporator coil fins and case assembly,
covering most of the contaminated area.
11. After 30 minutes, again with the mode set to recirculate, fan on HI, and temperature control to
maximum heat, start the engine and let it run at idle speed for 30 minutes. Make sure the windows
are open. This will dry and cure the Mitsubishi Cooling Coil Coating onto the evaporator coil.
12. Reinstall the glove box (and HVAC filter if applicable).
13. Reconnect the A/C clutch electrical connection (the receiver/drier pressure switch connector or
the clutch connector).
Page 4645
on actual vehicles.
Wire Color Codes
Page 1934
Page 5511
Stabilizer Link: Testing and Inspection
BALL JOINT BREAKAWAY TORQUE CHECK
1. After shaking the ball joint stud several times, install the nut to the stud and use the special tool
to measure the breakaway torque of the ball joint.
2. When the measured value exceeds the standard value, replace the ball joint. 3. When the

Refrigerant: Capacity Specifications CAPACITY
CAPACITY
594-653 Grams 1.31-1.44 Lbs.(US)

Page 5542
NOTE:
Ohms
Alignment - Two Wheel Vs. Four Wheel
Alignment: Technical Service Bulletins Alignment - Two Wheel Vs. Four Wheel
No: TT-127-00-001 DATE: June, 2006 MODEL See Below
SUBJECT: TWO WHEEL ALIGNMENT VERSUS FOUR WHEEL ALIGNMENT
Two Wheel Alignment versus Four Wheel Alignment - All models. When performing a two wheel
alignment, the steering and suspension components are adjusted to the vehicle centerline. We
then assume everything behind the front wheels is OK. However, bushings can wear, springs can
sag, collision damage and shifting of the subframe can all affect rear wheel alignment angles.
However, when performing a four wheel alignment, the angles in the rear are also measured and
taken into account.
On vehicles where adjustments are not possible (currently just the Raider) the thrust angle is
determined and the front wheels are aligned to it.
On vehicles where adjustments are possible (all current models except for Raider), the rear wheels
are first individually adjusted to the proper angles from the centerline. Then, the the front wheels
are adjusted to the proper angles from the centerline. After all adjustments have been made, the
vehicle will handle and track properly.
Page 1094
Engine Oil: Technical Service Bulletins Engine - Oil Recommendations/Obsolete Oils
No: TSB-05-12-001 DATE: January, 2005 MODEL: All Models
SUBJECT: OBSOLETE ENGINE OILS
PURPOSE
Mitsubishi recommends using only engine oils that meet or exceed the ILSAC GF-3 certification by
the American Petroleum Institute (API). Oils displaying this mark meet the current engine protection
standard and fuel economy requirements of the International Lubricant Standardization and
Approval Committee (ILSAC), which is a joint effort of U.S. and Japanese automobile
manufacturers. If this mark is not on the oil, be sure that the API service symbol on the oil meets
the appropriate service classification, as explained below.
The API rates the performance level of engine oils. After analyzing an oil in laboratory engines, the
API determines the oil's overall ability to lubricate, its resistance to wear, oxidation, corrosion, and
deposit formation.
API's Service Symbol on the oil container identifies the quality of the oil. Oils for gasoline engines
have API service classifications that begin with "S" (for service), followed by a letter to indicate the
performance level of the oil.
Only three API service classifications of engine oil are acceptable: SM, SL or SJ.
API's recommendations:
^ The latest engine oil service classification (as of November 30, 2004) is SM, for all automotive
engines currently in use. SM oils are designed to provide improved oxidation resistance, deposit
and wear protection, and better low-temperature performance over the life of the oil. Oils with SM
classification are most highly recommended for all model years, to prevent sludging.
^ SL (or SL/CF) oils are recommended for 2004 and older automotive engines.
^ SJ oils are recommended for 2001 and older automotive engines.
CAUTION
Engine oils with service classification of SH, SG, SF, SE, SD, SC, SB, or SA are obsolete oils that
should not be used. These oils may cause sludging, unsatisfactory engine performance, and may
damage engine components.
Authorized Mitsubishi dealers must use the proper oil classification during servicing. Recommend
customers to always be sure that their engine oil has a service classification of SM, SL or SJ,
depending on the vehicle's model year. If a non-authorized service facility is used, advise the
customer to confirm the engine oil classification with the service facility.
Page 5183
Auxiliary Power Outlet: Service and Repair For Rear Seat
Removal
Installation

Page 6745
Key Reminder Switch

Specifications
Operating Pressure

Page 3242
Fuel Injector: Description and Operation
OPERATION
- The injector is an injection nozzle with a solenoid which injects fuel according to the injection
signal coming from the engine control module.
- The injector has a fixed nozzle opening area and the fuel pressure against manifold inside
pressure is regulated to a fixed level. Therefore, the volume of fuel injected by the injector is
determined by the time during which the needle valve is open, namely, by the time during which the
solenoid coil is energized.
- The battery positive voltage is applied through the MFI relay to this injector. When the engine
control module turns on the power transistor in the unit, the solenoid coil is energized to open the
injector valve, which then injects fuel.
Page 2914


Page 2017

Federal
OPERATION
Page 2726
on actual vehicles.
Wire Color Codes
Page 4972
3.4 - 3.6 volts.
G-sensor.
Locations

Page 4102
Page 2266


Specifications
20° C (68° F) Approx. 1,200 Ohm
40° C (104° F) Approx. 500 Ohm

Page 2809
Removal
Installation
Page 1989
OPERATION
Page 2665

Page 499
HARNESS INSPECTION
(A5 - 92)
control module. -
(A1 - 81, A2 - 85)
Page 3816
Clutch: Specifications Direct Clutch
Disc Thickness (Limit) .........................................................................................................................

......................................... 1.84 mm (0.0724 inch) Drum Bushing Inner Diameter (Limit)
.......................................................................................................................................... 53.97 mm
(2.125 inch) Piston Stroke
.............................................................................................................................................................
1.37-1.67 mm (0.0539-0.0657 inch) Return Spring Free Length
...................................................................................................................................... Approximately
19.8 mm (0.780 inch)
Page 3405
Page 2021
on actual vehicles.
Wire Color Codes
Page 5172
Dedicated Fuse
Specifications
Vanity Lamp: Specifications
Vanity mirror light .................................................................................................................................
....................................................................... 1.5 W
Page 2514
Wire Color Codes
the marking color.

Page 5731
2. Drop or remove the glove box to gain access to the fan and duct assembly. On 1999-2003
Galants and 2000-2003 Eclipse with the A/C, heater, ventilation system filter, remove the filter
element.
NOTE:
The HVAC filter which must be removed was original equipment on 1999-2000 Galant and 2000
Eclipse. Be sure to check later models, also. This filter was a dealer installed option for 2001-03
Galant and Eclipse.
3. Set the A/C heater controls as follows:
^ Temperature control on HOT.
^ Fan on HI position
^ Air mode to RECIRC
^ Vent position to BI-LEVEL
4. Open all windows about 1/2 inch
5. Disconnect the air conditioner clutch electrical connection by removing the receiver/drier
pressure switch connector or by disconnecting the clutch connector at the compressor.
6. Place a protective cloth on the interior front carpet under the evaporator housing and duct. Start
the engine, letting it run at idle. As the engine idles with the heater controls set as instructed, hot air
recirculates over the evaporator raising the temperature of the evaporator, causing moisture to
evaporate faster. The open windows allow the moisture to escape without losing much heat. You
may see "fog" clouding the windows. After the fog disappears continue the operation for another 5
minutes. If the fog does not appear, continue with engine idling and the heater controls set for
another 30 minutes.
Page 3532
Ignition Coil: Application and ID
Type .....................................................................................................................................................
............................................................... Mold 3-coil Identification No. ...............................................
......................................................................................................................................... FC0020,
FC0021 Part No. ..................................................................................................................................
......................................................... MD314582, MD314583
Page 6395
5. Exterior Mouldings On some vehicles, exterior stainless steel mouldings can cause wind or
buzzing noise if not tightly fitted against the rubber retainer. Be sure they are firmly mounted.
The steel band must fit tightly into the rubber seal along its entire length.
6. Sunroof. Inspect the sunroof for proper alignment. Be sure the seals are secure.
Page 3442
Page 5384
Steering Gear: Testing and Inspection
BACKLASH CHECK
1. Jack up the vehicle front and hold the steering wheel in the straight-ahead position.
2. Use the special tool to disconnect the pitman arm from the relay rod.
CAUTION: -
Use cord to bind the special tool closely so it won't become separated.
- The nut should only be loosened, not removed.
3. Use a dial indicator to measure the steering gear backlash at the pitman arm top end.
4. If the measured value exceeds the limit, screw in the steering gear box adjusting bolt until the
steering wheel play is within the standard value
range.
CAUTION: -
Be sure to make the adjustment with the steering wheel in the straight-ahead position.
- If the adjusting bolt is overtightened, more steering effort will be required, and return of the wheel
will be adversely affected.
Page 6473
Grounding Markings

Fastener Tightening Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications Fastener Tightening Specifications
Damper Pulley Bolt ..............................................................................................................................

............................................ 182 Nm (134 ft. lbs.)
Page 5638
Wheel Fastener: Service and Repair
REPLACEMENT
1. Remove the caliper assembly and secure it with wire so that it does not fall. 2. Remove the
brake disc.
3. Use the special tool to remove the hub bolt.
CAUTION: Insert the spacer of thickness of approximately 3 mm between the special tool
(MB991618) and the dust cover to protect the dust cover.
4. Using the hub nut, tighten the hub bolt to install it.
Page 6742
on actual vehicles.
Wire Color Codes
Page 5220
Dedicated Fuse
Page 1952
Grounding Markings

Page 5131
Noise Suppressor Mounting Location
Component View
Noise Capacitor B
Page 5094

Page 3005


Specifications
Crankshaft Gear/Sprocket: Specifications

Page 4787
installation.
REAR REPLACEMENT
Page 3333


Page 664
on actual vehicles.
Wire Color Codes
Page 1873
Page 5409
Page 5625
Page 5940
B. CAUTION: SRS
frame.
F. CAUTION: SRS
G. WARNING: SRS
H. Danger: Poison.
medical attention.
J. CAUTION: SRS
key.
Page 3561
Measurement method
parts.
power transistor.

Page 4442

Page 856
selector lever.
Page 5589
Page 1838
sensor.

Page 71
RELAY VIEW

Page 3820
Page 6840
Brake Lamp: Application and ID
Stop light ..............................................................................................................................................
.......................................................... 32/2 (2057) cp

Page 6443
Page 5673
Cabin Temperature Sensor / Switch: Description and Operation
Page 340
sensor.

Page 4807
Grounding Markings

NOTE: -
(A1 - Ground)
(A2 - 88)
Diagrams
Page 3458


Page 4796
Brake Pedal Assy: Testing and Inspection
1. Turn up the carpet under the brake pedal. 2. Measure the brake pedal height (A) as shown in the
illustration. The standard value (A) is 186 - 191 mm (7.3 - 7.5 inch.) 3. Turn back the carpet.
1. Loosen the lock nut to sufficiently loosen the stop light switch. 2. Adjust the brake pedal height
by turning the operating rod with pliers (with lock nut loosened). 3. After turning the stop light switch
until it contacts the pedal stop (until immediately before the brake pedal begins to move), turn the
stop light
switch back 1/2 to 1 revolution and secure with a lock nut.
CAUTION:Check that the stop light is not illuminated when the brake pedal is not depressed.
NOTE:For vehicles with automatic transmission, check the shift-lock mechanism.
While the engine is stopped, depress the brake pedal two or three times. Thus, eliminating the
negative pressure in the brake booster, press the pedal down by hand, and confirm that the free
play (B) is within the standard value range. The standard value (B) is 3 - 8 mm (0.12 - 0.31 inch).
Page 4958
CONTROL UNIT VIEW
ABS Control Unit H
Page 6705
Page 3746
INSPECTION
Page 5405
Page 4340
Engine - Valve Lash Adjuster Cleaning Procedure
Lifter / Lash Adjuster: All Technical Service Bulletins Engine - Valve Lash Adjuster Cleaning
Procedure
NO: TSB-99-11-006 DATE: June, 1999 MODEL: See below
SUBJECT: VALVE LASH ADJUSTER CLEANING
PURPOSE
This bulletin contains cleaning procedures for valve lash adjusters. In many cases, cleaning valve
lash adjusters can extend their service life. Mitsubishi Motors strongly suggests cleaning and
inspecting lash adjusters before considering lash adjuster replacement.
AFFECTED VEHICLES
All models equipped with valve lash adjusters
PROCEDURE
! CAUTION
A Valve lash adjusters are precision mechanisms. Do not allow them to become contaminated by
dirt or other foreign substances. Do not attempt to disassemble valve lash adjusters. Use only
clean diesel fuel to clean valve lash adjusters.
1. Prepare three containers. Place enough diesel fuel into each container to cover a lash adjuster
when it is standing upright.
^ Container A will be used to clean the outside of the lash adjuster.
^ Container B will be used to clean the inside of the lash adjuster.
^ After cleaning the adjuster, use Container C to fill it with clean diesel fuel.
2. Place the lash adjuster into container A and clean its outside surface, using a nylon brush if
necessary.
Page 3805
1996 Montero Service Manual, Volume 1, Page 23C-6: Change the forward clutch piston stroke
specifications as shown.
Page 7155
Defogger Relay
Page 3161
NOTE:
Page 5330
3. Start the engine and idle it at (1,000 ± 100 rpm) 900 - 1,100 rpm. 4. Check whether or not the
hydraulic pressure is the standard value when no-load conditions are created by fully opening the
shut-off valve of the
pressure gauge. Standard value: 0.78 - 0.98 MPa (114 - 142 psi)
5. If it is not within the standard value, the probable cause is a malfunction of the oil line or steering
gear box, so check these parts and repair as
necessary.
the system.
Retention Hydraulic Pressure Check

3. Start the engine and idle it at (1,000 ± 100 rpm) 900 - 1,100 rpm. 4. Fully open the shut-off valve
of the pressure gauge. 5. Turn the steering wheel all the way to the left or right; then check whether
or not thee retention hydraulic pressure is the standard value.
Standard value: 8.31-9.00 MPa (1,205 - 1,305 psi)
6. When not within the standard value, overhaul the steering gear box.
Remeasure fluid pressure.
7. Remove the special tools, and the tighten the pressure hose to the specified torque. 8. Bleed the
system.
Page 6552
Rheostat
Rheostat
Page 5347


Page 6490
Grounding Markings

Page 1275
6. Remove the lash adjuster from container B. Then gently push down the steel ball and push the
7. Place the lash adjuster in container C. Then gently push down the internal steel ball using a stiff
wire (0.5 mm).
Do not use container C for cleaning. Foreign matter could enter the pressure chamber.
8. Stand the lash adjuster upright with its plunger at the top, then push the plunger downward firmly
until it moves through its furthest possible stroke. Return the plunger slowly, then release the steel
ball and allow the pressure chamber to fill with diesel fuel.
9. Remove the lash adjuster from container C and stand it upright with its plunger at the top. Push
the plunger firmly and check that it does not move.
If the lash adjuster contracts, repeat Steps 7 through 9 to fill it completely with diesel fuel. If it
contracts again, replace it.
10. Stand the lash adjuster upright to prevent the diesel fuel from spilling out. Do not allow it to
become contaminated by dirt or other foreign substances. Install it in the engine as soon as
possible.
Standard warranty procedures apply. Use the appropriate "Auto Lash Adjuster Cleaning" labor
operation code.
Page 4071
OPERATION
Page 4563
Grounding Markings

Page 3167

Page 4310
INSPECTION
INSTALLATION
Page 2898
Grounding Markings

Page 4192

Brake Lamp: Diagram Information and Instructions
Vacuum Brake Booster Check Valve: Testing and Inspection
NOTE: The check valve should not be removed from the vacuum hose.
OPERATIONAL CHECK
1. Remove the vacuum hose. 2. Check the operation of the check valve by using a vacuum pump.
3. A connection should be made at the brake booster side and a vacuum needs to be created (a)
and held. 4. Connect the vacuum pump at the intake manifold side and a vacuum should not be
created (b).
CAUTION: If the check valve is defective, replace it as an assembly unit together with the vacuum
hose.
Page 7124
Wire Color Codes
the marking color.

Page 5817
Service and Repair

Page 3301
Service and Repair
Heater Core: Service and Repair
INSPECTION

Fuel Gauge Unit
Float Point "F" ......................................................................................................................................

................................................................ 3 ± 2 Ohm Float Point "E" ..................................................
................................................................................................................................................ 110 ± 7
Ohm
Page 2022
Wire Color Codes
the marking color.

Page 497
OPERATION
module.
Page 2635

Page 1511
1997 Montero Service Manual, Volume 1, Page 11B-40 Correct the upper oil pan installation
Page 6604

Brush Holder: Testing and Inspection
Brush Holder
Check for continuity between the brush holder plate and the brush holder. The normal condition is
no continuity.
Page 4463
Page 1638
Front Crankshaft Seal: Service and Repair
1. Remove the timing belt. 2. Refer to the illustration for the service procedure, noting the following:
3. Cut out a portion in the camshaft oil seal lip.
seal.
CAUTION: Use care not to damage the crankshaft and oil pump case.
5. Using front seal installer tool No. MD998717, or equivalent, knock the oil seal into the oil pump
case.
NOTE: Knock it as far as the surface.

Page 842
NOTE:
Page 2919
Page 2688
Download Error

Ball Joint Torque
Ball Joint: Specifications Ball Joint Torque
Lower Arm
Lower Ball Joint And Knuckle Connection

...................................................................................................................................... 147 Nm (108
ft. lbs.) Lower Ball Joint And Lower Arm Connection
..................................................................................................................................... 81 Nm (60 ft.
lbs.)
Upper Arm
Upper Ball Joint And Knuckle Connection

.......................................................................................................................................... 74 Nm (54
ft. lbs.) Upper Ball Joint And Upper Arm Connection
...................................................................................................................................... 25 Nm (19 ft.
lbs.)
Spark Plug Cable

Page 5840

- Clock Spring
- Air Bag Module
Service Precautions
table.
SRS-ECU Connector
Page 935
Page 2690
database number.
Page 6787
Transmission Shift Position Indicator Lamp: Description and Operation
- When the ignition key is turned to the "ON" position, the indicator illuminates to indicate the
position at which the selector lever is set.
Page 3844
Limit: 1.84 mm (0.0724 inch)
the limit.
NOTE: -
Page 767
Torque 1.5 ft.lb

Corrections
DTCs.
NOTE:

Page 3298


Locations
Tail Lamp Relay: Locations

INSPECTION
BLOWER SWITCH
Page 6551

Page 5150
Service and Repair
Ignition Lock Cable: Service and Repair
Page 3355
on actual vehicles.
Wire Color Codes
Page 4596
Page 1876
Water Pump: Service and Repair
1. Drain the engine coolant. 2. Remove the timing belt. 3. Refer to the illustration for the service
procedures, noting the following:
- When installing the O-ring, rinse the mounting location of the O-ring and water pipe with water,
and install the O-ring and water pipe.
NOTE: -
Do not apply oil and grease to water pipe O-ring.
- Keep the water pipe connections free of sand, dust etc.
- Insert water pipe until its end bottoms.

Page 2136


Page 3116

Page 5851
1997 Eclipse/Eclipse Spyder, Volume 1, page 52B-5
Component Testing
EGR Control Solenoid: Testing and Inspection Component Testing
1. Disconnect the vacuum hose from the solenoid valve. 2. Disconnect the harness connector.
3. Connect a hand vacuum pump to the nipple to which the green-striped vacuum hose was
connected.
4. Apply a vacuum and check for air-tightness when voltage applied directly to the EGR solenoid
and when the voltage is discontinued.

Page 5372


Page 4451

control module.
Page 6888

Page 1931

Page 313
Page 3838
NOTE: -
CAUTION: -

Page 779
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A1 - 92)
control module. -
Page 2940
follows.
that position.
Page 5602
Use only cable chains that meet SAE "S" clearance specifications.
Page 3018
Page 3631
Spark plug ID
NGK .....................................................................................................................................................
................................................................PFR5J-11
Denso ..................................................................................................................................................
............................................................PK16PR-P11
Speedometer Check
Speedometer Head: Testing and Inspection Speedometer Check
Speedometer Check
1. Adjust tire pressure to the specified level. 2. Place the vehicle on a speedometer tester and
chock the front front wheels.
CAUTION: Always inspect with the transfer ever in the 2H position.
3. Check that the speedometer indication range is within the standard values.
CAUTION: Do not operate the clutch suddenly or decrease speed rapidly while testing.
Standard Value: Standard Indication mph
Allowable Range mph
20 19 - 22
40 38 - 44
60 57 - 66
80 76 - 88
100 94 - 110
Page 5501

Locations
Fuse: Locations
Name Symbol
Fusible Links 1-7 A
Page 2246
Grounding Markings

Page 1589

Page 753
Grounding Markings

Page 168
on actual vehicles.
Wire Color Codes
Page 3999
INSTALLATION
the cable band.
Locations

INSPECTION
Page 1615
Wire Color Codes
the marking color.

Page 558
Removal
Installation
Page 2579
Page 2500
Page 2511

Page 2725


Page 1830
Grounding Markings

Page 3872
Fluid - A/T: Fluid Type Specifications
Transmission fluid
Type
......................................................................................................................................................
DIAMOND ATF SP or DEXRON II or Equivalent
Page 3854
DISASSEMBLY
INSPECTION

NOTE: -
ASSEMBLY

Page 6049
Grounding Markings

Page 5888
2. When disconnecting the connector of the clock spring from the air bag module, press the air
bag's lock toward the outer side to spread it open. Use
a screwdriver to pry gently as shown in the figure at the left, to remove the connector.
CAUTION: 1. Wait disconnection the air bag module-clock spring connector, take not to apply
excessive force to it.
2. The removed air bag module should be stored in a clean, dry place with the pad cover face up.
Step 4: Steering Wheel Removal
CAUTION: Do not hammer on the steering wheel. Doing so may damage the collapsible column
mechanism.
1. When installing the new air bag module and clock spring, refer to "INSPECTION"
CAUTION: Dispose of an air bag module only according to the specified procedure.
2. Connect the battery (-) terminal.
3. Connect the scan tool to the data link connector then check diagnostic codes.
4. Turn the ignition key to the "ON" position. 5. Conduct diagnostic test using the scan tool to
ensure entire SRS operates properly.
Page 3300
Wire Color Codes
the marking color.

Page 2660
Component View
Page 6381

Page 6858
Page 1081
Fluid - Differential: Fluid Type Specifications
Front Differential and/or Conventional Rear Differential
API GL-5 or higher
Above -23°C (-10°F) ............................................................................................................................

....................................... SAE 90, 85W-90, 80W-90 From -34°C (-30°F) to -23°C (-10°F)
..................................................................................................................................................... SAE
80W, 80W-90 Below -34°C (-30°F) .....................................................................................................
......................................................................................... SAE 75W
Rear Limited Slip MITSUBISHI Genuine Gear Oil, Part No. 8149630 EX or equivalent
Free Play Check
Steering Wheel: Testing and Inspection Free Play Check
1. When the engine is stopped and the steering wheel is in the straight-ahead position, apply a
force of 5 N (1.1 lbs.) to the steering wheel in the
peripheral direction. Measure the play on the circumference of the steering wheel. Standard value:
26.6 mm (1.05 inch) or less Limit: 50 mm (1.97 inch)
2. If the measured value exceeds the repair limit, check the steering gear backlash and linkage ball
joint end play.
Locations

Part 1 Of 3
Page 6225
CAUTION:

Page 5091

Page 2430
OPERATION
Page 3771
INSPECTION
the ground.
Page 6701


Roof Rack - Wind Noise/Paint Peeling
Roof Rack Frame: All Technical Service Bulletins Roof Rack - Wind Noise/Paint Peeling
NO: TSB-98-51-003 DATE: May, 1998 MODEL: 1992-98 Montero
SUBJECT: ROOF RACK WIND NOISE/PAINT PEELING
PURPOSE
On some vehicles, the paint may begin to peel from the roof rack surface. To correct this condition,
a roof rack service kit containing side rails and cross-bars with improved paint is available. The
service kit components have also been redesigned to reduce wind noise.
Recent vehicle shipments have a new roof rack system which also has the improved paint and new
design. The new roof rack system can be identified by the four tie-down loops. (Original roof racks
have eight tie-down loops.)
The service kit cross-bars do not have tie-down loops. If a customer so desires, the original
cross-bar tie-down loops can be transferred to the new cross-bars. However, if this is done the
cross-bar filler strip must be shortened to accommodate the tie-down loops.
Typically, the original rub strips can be re-used. Do not replace the rub strips unless the original
ones are coming loose.
AFFECTED VEHICLES
1992-98 Montero models equipped with roof rack
PARTS INFORMATION
Normal warranty procedures apply.

Page 2292
follows.
that position.
Page 2516
OPERATION
INSPECTION
Using Scan Tool
HARNESS INSPECTION
NOTE:
Page 2970
Grounding Markings

Specifications

........................................... 35 Nm (26 ft. lbs.)
Page 2445
OPERATION
module.
Page 3498

SENSOR VIEW

Locations

Carpet: All Technical Service Bulletins Recall - Rear Cargo Mat
NO: SR-98-004
DATE: October, 1998
PURPOSE
Remedy
area mat
NOTE:
Page 2466
increased.

Locations
CONTROL UNIT VIEW

Snap Ring (Adjustment of Bearing End Play)
Page 5560

Specifications
Malfunction Indicator Lamp: Specifications
Check engine/malfunction indicator lamp ............................................................................................
...................................................................... 1.12 W
Page 6760
Page 3284
Point F:.................................................................................................................................................
..................................................3 ± 2 Ohms Point E:...........................................................................
...................................................................................................................110 ± 7 Ohms
touching stopper.
Standard value:
A:..........................................................................................................................................................
..........................................119.3 mm (4.69 in.) B:................................................................................
..................................................................................................................255.0 mm (10.03 in.)
Page 2616

Page 5202

Page 2347
Specifications
Fan Blade: Specifications
Mounting Bolt .......................................................................................................................................

................................................. 11 Nm (8 ft. lbs.)
Page 1921


Page 332
Grounding Markings

NOTE: -
(A1 - Ground)
(A2 - 88)
Page 6261
CONTROL UNIT VIEW
Specifications
.............................................................................................................................................. 1.12 W

Switch Adjustment
V4AW2 A/T.
23A-45
Page 3440
on actual vehicles.
Wire Color Codes
Basic Idle Speed
readjustment.
procedure.
grounded.


Page 5952

Page 358
Page 4170
B. Side bearing inner race removal. (6)
Use the special tools to pull out the side bearing inner races.
C. Drive gear removal. (8)
1. Make mating marks on the differential case and drive gear. 2. Loosen the drive gear mounting
bolts in diagonal sequence to remove the drive gear.
D. Lock pin removal. (9)
Drive out the lock pin with a punch.
NOTE: The removed side gears and the left and right side gear thrust spacers should be retained
for reassembly.
E. Companion flange self-locking nut removal. (16)
Use the special tool to hold the companion flange, and then remove the companion flange
self-locking nut.
Page 4072
Ignition switch-ST
HARNESS INSPECTION
module. -
NOTE: -

Page 3025

Page 870
on actual vehicles.
Wire Color Codes
Page 233
on actual vehicles.
Wire Color Codes
Page 2489

Page 3511
harness. (A3 - B1)
(A1 - Ground)
harness. (A2 - 89)
Page 3022
Component View
Page 4232
Wire Color Codes
the marking color.

Page 4032
Sun Gear: Service and Repair
DISASSEMBLY
INSPECTION
NOTE: -
ASSEMBLY

Page 4814
Brake Warning Indicator: Description and Operation
the engine has started. This warning light illuminates when the parking brake is applied or when the
brake fluid level falls to less than the specified level.
Page 5074
NOTE:
Page 1581
Intake Manifold: Service and Repair Intake Manifold Plenum
Automatic
1. When removing the throttle body, leave the water hoses attached to the assembly. 2. Refer to
the illustration for removal procedure. 3. Reverse procedure to install, noting the following:
- Install with gasket protrusion in the position illustrated.
- Be sure to adjust the accelerator cable.
- Also, adjust the throttle cable.
Manual
Page 4786
FRONT REPLACEMENT
Key Reminder Buzzer Check
Audible Warning Device: Testing and Inspection Key Reminder Buzzer Check
Key Reminder Buzzer Check
1. Apply battery positive voltage between terminal 2 and terminal 10. 2. Check that the buzzer
sounds intermittently when terminal 3 is grounded.
Page 5772
COOL). 23. Fix the engine speed at 1,500 r/min. 24. Tighten the handle of the adaptor valve (valve
open) to charge the required volume of refrigerant.
in gas state.
25. After charging with refrigerant, turn the handle of the adaptor valve back all the way (valve
closed). 26. Tighten the charge valve handle (valved closed). Disconnect the quick joint (for low
pressure) from the low-pressure service valve.
CORRECTING LOW REFRIGERANT LEVEL WHEN THE BULK CONTAINER IS USED
1. Install the adaptor valve with the handle turned all the way in (valve closed) to the charge valve.
2. Connect the charging hose (blue) to the adaptor valve. 3. Connect the charging hose (blue) to
the quick joint (for low pressure). 4. Open the valve of the bulk container. 5. Turn the handle of the
adaptor valve to bleed the air.
6. Connect the quick joint (for low pressure) to the low pressure service valve.
COOL). 9. Fix the engine speed at 1,500 r/min.
10. Tighten the handle of the adaptor valve (valve open) and replenish refrigerant while checking
the quantity through the sight glass.
CAUTION: If the bulk container is inverted, liquid refrigerant may be draw into the compressor,
in gas state.
11. After replenishing is completed, turn the handle of the adaptor valve all the way in (valve
closed) and disconnect the quick joint.
METHOD USING A REFRIGERANT RECOVERY AND RECYCLING UNIT
Use the refrigerant recovery and recycling unit to refill with refrigerant.
Page 339
INSPECTION
Using Scan Tool
HARNESS INSPECTION
harness. (A2 - 92)
(A1 - 83)

Page 3483

Page 55
(Part 1 Of 2)
Page 482
Page 4443
Grounding Markings

Page 862

Page 3457

Page 1538
Multi Meter
Page 3826
Page 2838


Page 6056
Radio/Stereo: Service and Repair
Removal
Installation

Page 5876
Air Bag: Technical Service Bulletins Air Bag - Minimizing Deployment Risk
NO.: TSB-97-52B-001 DATE: February, 1997 MODEL: All SRS Models
SUBJECT: AIR BAG DEPLOYMENT OUTSIDE THE VEHICLE
This bulletin supersedes TSB-91-52B-002, to include all SRS-equipped models and front
passenger air bags.
BACKGROUND INFORMATION Air bags are deployed by activating a small quantity of sodium
azide, which is considered toxic when in its solid state. When ignited, sodium azide releases a
large volume of non-toxic nitrogen gas to inflate the air bag. Deployment is sudden because the
nitrogen gas is produced very rapidly. Precautions must be taken when deploying an air bag
outside of the vehicle.
PURPOSE Follow the precautions and procedures in this bulletin to minimize risk of personal injury
when deploying an air bag module outside of the vehicle.
AFFECTED VEHICLES
All models equipped with Supplemental Restraint System (air bags):
PRECAUTIONS AND PROCEDURES
! WARNING
1. To avoid personal injury, air bag deployment must be done on a wide, level ground without any
persons or obstacles within a 20 foot radius.
2. Do not deploy air bags in residential areas. A loud noise will be heard when the air bag module
is deployed. If anyone is nearby, warn them of the noise before deploying the air bag. Anyone near
the deployment area should wear ear protection.
3. Smoke is produced when the air bag is deployed. Select a well-ventilated area far away from a
smoke detector. Though not poisonous, do not inhale the smoke.
4. Wear safety glasses and heavy gloves when handling an air bag module. If residue material
does get into your eyes or on your skin, immediately rinse the affected area with large quantities of
clean water. If any irritation develops, seek medical attention immediately.
5. Place the air bag module downwind of yourself and the deployment battery. Do not deploy the
air bag module under windy conditions.
! WARNING
After disconnecting the battery cables, wait at least 60 seconds before proceeding. The SRS
system is designed to retain enough voltage to deploy the air bag for a short time after the battery
has been disconnected. Unintentional deployment can cause serious injury.
DEPLOYMENT PROCEDURE

SRS Maintenance
them with new ones.
A. WARNING
injury.
Specifications
..................................................................... 1.12 W
Page 1023
- Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and
tensioner must be kept free from oil and water. Do not immerse parts in cleaning solvent.
- If there is oil or water on any part, check the front case oil seal, camshaft oil seal and water pump
for leaks.
3. Use end yolk holder and two pulley holding pins tool Nos. MB990767 and MD998715, or
equivalents to loosen/tighten the camshaft sprocket
bolt.
4. If the auto tensioner rod is fully extended, set it in the retracted position with the following
procedure:
a. Set the auto tensioner in a vice.
b. Slowly close the vice to force the rod in until the set hole (A) of the rod is lined up with the set
hole (B) of the cylinder. c. Insert a wire 1.4 mm (0.055 inch) in diameter into the set holes. d.
Remove the auto tensioner from the vice.
5. When installing the timing belt, proceed as follows:
a. Move the timing mark of the crankshaft sprocket three teeth to slightly lower the piston below the
top dead center on the compression stroke of
the No. 1 cylinder.
CAUTION: If the camshaft sprocket is rotated with the piston at TDC on the compression stroke of
the No. 1 cylinder, the valve and piston might interfer with one another.
Locations

Locations

Output Voltage
Voltage 0.6 - 1.0 V

Page 3330

Page 6052
on actual vehicles.
Wire Color Codes
Page 2447
HARNESS INSPECTION
(A5 - 92)
control module. -
(A1 - 81, A2 - 85)
Page 2784
Wire Color Codes
the marking color.

Page 3683
INSPECTION
measurements

Page 4750
RELAY VIEW

Page 4180
4. Install the side bearing adjusting spacers and differential case assembly to the gear carrier as
shown in the illustration.
5. Tap the side bearing adjusting spacers with a brass bar to press-fit them to the side bearing
outer race.
6. Align the mating marks on the gear carrier and the bearing cap, and then tighten the bearing
cap.
7. With the drive pinion locked in place, use a dial indicator to measure the final drive gear
backlash on the drive gear.

Page 2053

SENSOR VIEW

Page 5112
RELAY VIEW
Starter Relay E
Page 6156

procedures apply.
Technical Service Bulletin # 97-42A-007 Date: 970401
PURPOSE
AFFECTED VEHICLES
1992-97 Montero
PROCEDURE

Page 2682
reprogramming.
Page 3334
on actual vehicles.
Wire Color Codes
Page 2174


Page 5562
on actual vehicles.
Wire Color Codes
Page 5015
Bolt ......................................................................................................................................................
...................................... 13 Nm (108 inch lbs.) Nut .............................................................................
................................................................................................................. 4 Nm (34.8 inch lbs.)
Page 5853
1997 Galant, Volume 1, page 52B-5

Page 6371
operation.
rear wheel housing.
c. Tighten bolt A.
d. Tighten bolt B.
f. Tighten bolts C.
PARTS INFORMATION

Page 6331
CONTROL UNIT VIEW
Oil Pan: Mechanical Specifications
Lower
1. Remove sealant from oil pan and cylinder block mating surfaces. 2. Degrease the sealant coated
surface and the engine mating surface. 3. Apply Mitsubishi Genuine Part No. MD970389, or
equivalent sealant, around the gasket surface of oil pan as specified in illustration.
diameter.
12 Nm (7 - 9 ft. lbs.).
Upper
1. Ensure that all the sealant from the oil pan and cylinder block mating surfaces is removed.
Page 2019

Specifications
Coolant Drain Plug: Specifications
Sealant
..........................................................................................................................................................
3M Nut Locking Part No. 4171, Or Equivalent
Page 1216
Wheels: Testing and Inspection
WHEEL RUNOUT CHECK
Jack up the vehicle so that the wheels are clear of the floor. While slowly turning the wheel,
measure wheel runout with a dial indicator. Limit:
Radial runout: 1.0 mm (.04 inch) Lateral runout: 1.0 mm (.04 inch)
If wheel runout exceeds the limit, replace the wheel.

Page 3513
increased.

Page 528

Page 1954


Page 1308
c. Push the rocker arm in the locations indicated by the white arrow mark as shown in the
illustration at left to check if the rocker arm moves
down or not.
d. Slowly turn the crankshaft 360° clockwise. e. Check the rocker arm in the locations indicated by
the black arrow mark as shown in the illustration, using the same procedure as in step c.
f. If the rocker arm can be lowered easily when the part of the rocker arm which is directly above
the top of the lash adjuster is pressed, the lash adjuster is defective and should be replaced with a
new part. Furthermore, when replacing the lash adjuster, bleed all of the air from the lash adjuster
and then install. Check that there is no abnormality by carrying out the inspection in steps a to c.
NOTE: -
A leak-down test can be carried out to accurately determine whether the lash adjuster is defective
or not.
- If the rocker arm feels extremely stiff and cannot be lowered when it is pressed, the lash adjuster
is normal, so investigate for another cause of the abnormality.
[1] After gradually increasing the engine speed from idle speed to 3000 RPM (over 30 seconds),
gradually reduce the engine speed back to idle speed (over 30 seconds).
Page 6544


Page 2115
Wire Color Codes
the marking color.

Page 1143

- Clock Spring
- Air Bag Module
Service Precautions
table.
SRS-ECU Connector
Page 684
Wire Color Codes
the marking color.

Page 1461
Drive Belt: Specifications A/C
When checked .....................................................................................................................................

............................. 6.5 - 7.5 mm (0.26 - 0.30 inch) When new belt is installed
................................................................................................................................................ 5.0 -
............................................................................................................................................... 6.5 - 7.5
mm (0.26 - 0.30 inch)
Page 1519
Page 6514
on actual vehicles.
Wire Color Codes
Page 777
Specifications
Throttle Valve Assembly: Specifications
Throttle Valve Cam ..............................................................................................................................

.................................... 10 Nm (86.4 inch lbs.)
Page 3494
Removal
Installation
Page 4870
CAUTION: -
When removing the pistons, be sure to use the handle of a plastic hammer and adjust the height of
the two pistons while pumping in air slowly in so that the pistons protrude evenly.
- Do not remove one piston completely before trying to remove the other piston because it will
become impossible to remove the second piston.
Page 2868
SENSOR VIEW

Locations
COMPONENT VIEW VIEW

Page 4046
6. Observe the amount of clean ATF output in 20 seconds. Turn off the engine.
a. If less than one quart of fluid is output in 20 seconds, there may be a restriction in the oil
cooler(s). Perform Steps 7 through 9.
b. If one quart or more of fluid is output in 20 seconds, go to Step 10.
7. Empty the graduated container. Disconnect the inlet line to the oil cooler and place the line in the
empty container.
8. With the inlet line from the oil cooler placed in the container, start the engine in Neutral and
watch for clean ATF flow (no bubbles or foam).
Continue until the ATF flows clean and the fluid level reaches the 1-quart mark. Then start the timer
for the flow test.
9. Observe the amount of clean ATF output in 20 seconds. Turn off the engine.
a. If less than one quart of fluid is output in 20 seconds, replace the transmission. Then repeat
Steps 2 through 6 to verify there is no restriction in the oil cooler(s).
b. If one quart or more of fluid is output in 20 seconds, replace the radiator. Then continue with
Step 10.
IMPORTANT:
On models equipped with an auxiliary oil cooler, remove the line to the auxiliary oil cooler from the
radiator and repeat Steps 2 through 4 for flow testing.
10. Reconnect the cooler line and fill the transaxle to the proper level. Check fluid level with the
transmission in the Neutral position at normal operating temperature. (Checking the ATF level in
Park may give an incorrect fluid level reading.) Inspect and repair any leaks as necessary.
Every automatic transmission replacement or major transmission repair (e.g., torque converter or
valve body replacement) must have both a back flush and a flow test performed The flow test must
be documented and the test results retained in the vehicle file.
The flow test results must also be recorded in the related warranty claim's "Condition, Cause and
Remedy" section.
IMPORTANT:
Warranty claims for A" replacements or major transmission repairs (e.g., torque converter or valve
body replacement) where a backflush procedure and a documented flow test were not performed
are subject to debit action.
Page 892
Meter
Volt Meter Gauge: Service and Repair Electronic Compass, Oil Pressure Gage and Voltage Meter
Disassembly Steps
Disassembly
Reassembly

Service and Repair
Removal
Installation

Page 5080
INSTALLATION
the cable band.
Specifications

............................................ 15 Nm (11 ft. lbs.)
Page 2629

Page 2217
on actual vehicles.
Wire Color Codes
Page 420


Front Suspension
Alignment: Service and Repair Front Suspension
Toe-In
1. Measure the toe-in.
Standard value:
Wheel): 0° to 0° 17'
2. If the toe-in is not within the standard value, adjust the toe-in by turning the left and right tie rod
turnbuckles by the same amount (in opposite
directions).
CAUTION: The difference between the left and right tie rods should not exceed 5 mm (.2 inch).
3. After adjusting, use a turning radius gage to confirm that the steering wheel turning angle is
within the standard value range.
Toe-Out Angle on Turns
To check the steering linkage, especially after the vehicle has been involved in an accident or if an
accident is presumed, it is advisable to check the tow-out angle on turns in addition to the wheel
alignment. Conduct this test on the left turn as well as on the right turn.
Standard value: 21° 56' (inner wheel when outer wheel at 20°)
Camber
Standard value: (0° 40' ± 30') -1° 10' to -0° 10' (Left/right deviation within 30') 1. Adjust the camber
by increasing or decreasing the thickness of the adjusting shim provided between the upper arm
shaft and the crossmember.
NOTE: -
Standard thickness of the shim is 4 mm (.16 inch).
- The number of shims is three or less.
Camber adjustment shim (yellow plating):
Part number Thickness
MB176288 1.0 mm (.039 inch)
MB176289 2.0 mm (.079 inch)
Caster
Standard value: (3° 00' ± 1° 00') 4° 00' to 2° 00' (Left/right deviation within 30')
1. Caster is preset at the factory and cannot be adjusted. 2. If caster is not within the standard
value, replace bent or damaged parts.
Page 2648
OPERATION
Page 6516
Clock
No.: TSB-95-52B-002


Switch Adjustment
V4AW2 A/T.
23A-45
Specifications
Brake Warning Indicator: Specifications
Brake warning light ..............................................................................................................................
...................................................................... 1.12 W
Page 4633
Part 3 Of 3
Page 4235
INSPECTION
measurements

Page 4345
2. Use the plug as a cover so that no foreign material gets into the transmission or transfer.
INSPECTION
1. Check the universal joints for smooth operation in all directions. 2. Check the sleeve yoke and
flange yoke for wear, damage or cracks. 3. Check the propeller shaft yokes for wear, damage or
cracks. 4. Check the propeller shaft for bends, twisting or damage.
Propeller Shaft Runout
Measure the propeller shaft runout with a dial indicator. Limit: 0.6 mm (0.024 inch)
INSTALLATION
A. Front propeller shaft/rear propeller shaft installation. (1 & 2)
CAUTION: Be careful not to damage the oil seal lip of the transmission and transfer.
Page 665
Wire Color Codes
the marking color.

Page 2467
Removal
Installation
Page 1775
sensor.

Page 3096

Page 2321

Power Window - Motor & Regulator Assembly Procedures
Window Regulator: Technical Service Bulletins Power Window - Motor & Regulator Assembly
Procedures
NO. TSB-97-42A-003 DATE: February, 1997 MODEL: See Below
PURPOSE
In the past, the power window motor and regulator were supplied as a complete unit for
replacement parts. For listed models the motor and regulator are now available separately. The
affected service manuals do not include instructions for motor and regulator assembly or drum and
regulator wire assembly. Use the instructions in this bulletin along with those in the service manual
when replacing the power window motor and/or regulator.
AFFECTED VEHICLES 1992-97 Montero 1992-95 Expo/Expo LRV
AFFECTED MANUALS The following manuals do not include the procedures covered in this
bulletin for power window motor/regulator assembly and drum and regulator wire assembly.
1992-95 Montero Service Manual Volume 1 1996 Montero Service Manual Volume 1 1997 Montero
Service Manual Volume 1 1992-96 Expo/Expo LRV Service Manual Volume 1
PROCEDURE ^
POWER WINDOW MOTOR AND REGULATOR ASSEMBLY
CAUTION
Be careful when handling the power window motor. otherwise, the wire may come off the drum due
to the reaction force of the spring.
1. The new part comes with a tie-wrap to hold the assembly together during shipping. This tie must
be removed before proceeding. While holding the case and metallic cover by hand, cut off the
tie-wrap with side cutters or similar tool.
2. Remove the metallic cover.
Note:
If the wire has come off of the drum, restore the wire according to the DRUM AND REGULATOR
WIRE ASSEMBLY procedures elsewhere in this bulletin.
3. Using the guide and motor housing opening and drum housing guide tab as assembly reference
points, align the drive shaft of the power window
Page 5344

Page 5915

Page 2208
Page 2187

SENSOR VIEW

Snap Ring (For Adjustment of Input Gear Bearing End
Play)
Page 2006
Wire Color Codes
the marking color.

Page 2597
Idle Speed/Throttle Actuator - Electronic: Description and Operation
OPERATION
- The amount of air taken in during idling is regulated by the opening and closing of the servo valve
located in the air passage that bypasses the throttle valve.
- The servo valve is opened or closed by the activation of the stepper motor (incorporated within
the idle air control motor in the forward or reverse direction.
- Battery positive voltage is supplied, by way of the MFI relay, to the coil of the stepper motor. The
engine control module switches ON the power transistors (located within the engine control
module) in sequential order, and, when current flows to the stepper motor coil, the stepper motor is
activated in the forward or reverse direction.
Page 3976
Page 4792
Page 4381
Fluid - M/T: Fluid Type Specifications
API classification GL-4 SAE 75W-85W, 75W-90
Page 2201
harnesses.
Page 5552
Suspension Strut / Shock Absorber: Mechanical Specifications
Front Suspension
Stroke
Standard ..............................................................................................................................................
.................................................. 120 mm (4.7 inch) Optional * ............................................................
................................................................................................................................. 115 mm (4.5
inch)
Damping Force [at 0.3 m per sec. (0.9 ft. per sec.)]
Expansion:
Standard ..............................................................................................................................................
............................................. 2,450 N (540 lbs.) Optional *:
Hard .....................................................................................................................................................
...................................... 3,150 N (694 lbs.) Medium ...........................................................................
........................................................................................................... 2,350 N (518 lbs.) Soft .............
..............................................................................................................................................................
.................. 1,700 N (375 lbs.)
Contraction:
Standard ..............................................................................................................................................
............................................. 1,500 N (331 lbs.) Optional *:
Hard .....................................................................................................................................................
...................................... 1,600 N (353 lbs.) Medium ...........................................................................
........................................................................................................... 1,250 N (276 lbs.) Soft .............
..............................................................................................................................................................
..................... 850 N (187 lbs.)
Length
Maximum .............................................................................................................................................
............................................... 345 mm (13.6 inch) Minimum:
Standard ..............................................................................................................................................
............................................ 225 mm (8.9 inch) Optional * ..................................................................
..................................................................................................................... 230 mm (9.1 inch)
Attaching Dimension
Standard Value:
Standard ..............................................................................................................................................
.................................. 1 - 2 mm (.04 - .08 inch) Optional * ..................................................................
...................................................................................................... 1.5 - 2.5 mm (.06 - .10 inch)
Tightening Specifications
Shock Absorber Mounting Nut (Lower Side)

........................................................................................................................... 88-103 Nm (65-76 ft.
lbs.) Shock Absorber Mounting Nut (Upper Side)
........................................................................................................................................ 15 Nm (11 ft.
lbs.)
NOTE: (*) Vehicles with optional remote-controlled variable shock absorbers.

Rear Suspension
Damping Force [at 0.3 m per sec. (0.9 ft. per sec.)]
Expansion:
Standard ..............................................................................................................................................
............................................. 2,450 N (540 lbs.) Optional *:
Hard .....................................................................................................................................................
...................................... 3,350 N (739 lbs.) Medium ...........................................................................
........................................................................................................... 2,450 N (540 lbs.) Soft .............
..............................................................................................................................................................
.................. 1,750 N (386 lbs.)
Contraction:
Standard ..............................................................................................................................................
............................................. 1,300 N (287 lbs.) Optional *:
Hard .....................................................................................................................................................
...................................... 1,650 N (364 lbs.) Medium ...........................................................................
........................................................................................................... 1,300 N (287 lbs.) Soft .............
..............................................................................................................................................................
..................... 900 N (198 lbs.)
Length
Maximum .............................................................................................................................................
............................................... 457 mm (18.0 inch) Minimum ..............................................................
.............................................................................................................................. 297 mm (11.7 inch)
Stroke ..................................................................................................................................................
..................................................... 160 mm (6.3 inch)
Protruding length of mounting bolt

................................................................................................................................................. 1-2
mm (.04-.08 inch)
Distance between actuator mounting surface and shock absorber stud end: 1.5-2.5 mm (.06-.10
inch)
Tightening Specifications
Page 2685
main menu.
reprogramming.
Torque 1.5 ft.lb

Locations
Name Symbol
Fusible Links 1-7 A
Page 3701

Page 6542
Grounding Markings

Page 2312
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Page 5248
side.

Page 6874
Cargo Lamp: Testing and Inspection
1. When the doors are opened, the dome light or cargo space light does not illuminate for certain
doors,
- Check the front or rear door switch.
- Check the back door switch.
2. When the dome light switch or cargo space light switch is set to the DOOR position and any of
the doors are opened, the dome light or cargo
space light does not illuminate. a. Illuminates when the switch is at the ON position.
b. It does not illuminate even if the switch is at the ON position.

Page 2158
Grounding Markings

Page 5315
Power Steering Fluid: Service and Repair Fluid Replacement
Check for contamination in the fluid reservoir. Foamy or cloudy fluid should be replaced. 1.
Remove the reservoir cap. 2. Disconnect the return hose from the reservoir tank and remove the
fluid. 3. Disconnect the high tension cable. 4. Run the engine intermittently several times with the
starting motor to remove the fluid from the gear box. 5. Attach the return hose and fill with the
specified automatic transmission fluid.
6. Bleed the system and check the fluid pressure.

Page 4167
NOTE: The measurement should be made for both pinion gears individually.
Standard value: 0.076 mm (0.0030 inch) or less Limit: 0.2 mm (0.0079 inch)
2. If the backlash exceeds the limit, adjust by using the side gear thrust spacers.
Final Drive Gear Tooth Contact
Check the final drive gear tooth contact by the following procedure:
1. Apply a thin, uniform coat of machine blue to both surfaces of the drive gear teeth.
2. Insert a brass rod between the differential carrier and the differential case, and then rotate the
companion flange by hand (once in the forward
direction, and then once in the reverse direction) while applying a load to the drive gear, so that the
rotation torque [2.5-3.0 Nm (28-33 in.lbs.)] is applied to the drive pinion.
CAUTION: If the drive gear is rotated too much, the tooth contact pattern will become unclear and
difficult to check.
Page 119
reprogramming.

Page 4465
Correction
PURPOSE
AFFECTED VEHICLES
PROCEDURE
NOTE:
Page 518
increased.

Page 2388
GAP

Page 2757


Page 164

Page 3597
OPERATION
Page 599

Page 5672
Page 4437
Service and Repair
Removal
Installation

Page 1962
RELAY VIEW

Fluid - Transfer Case: Capacity Specifications
SPECIFIED LUBRICANTS Transfer Oil Quantity
.............................................................................................................................................................
Approximately 2.5 L (2.4 qts.)
Catalytic Converter: Testing and Inspection
CAUTION: 1. Stop the engine immediately if engine misfiring occurs, otherwise an abnormally hot
exhaust system will damage the catalytic converter or
other underbody parts.
2. Correct and repair the ignition or fuel system if there are malfunctions, otherwise engine misfiring
may occur which will damage the catalytic
converter.
3. Observe manufacturer's specifications when doing service work.

Page 3190
Fillpipe Restrictor: Testing and Inspection
Remove the fuel filler cap and check the fillpipe restrictor for tampering. On models with more that
one fuel tank, check each tank filler tube.
Automatic Transmission
Backup Lamp: Testing and Inspection Automatic Transmission
The back-up lights do not illuminate. -
Check the park/neutral position switch.
- Check the back-up light bulb.

Page 4376
Page 5273

Page 6550

Locations
RELAY VIEW

Page 4185
2. Insert a brass rod between the differential carrier and the differential case, and then rotate the
companion flange by hand (once in the forward
direction, and then once in the reverse direction) while applying a load to the drive gear, so that the
rotation torque [2.5-3.0 Nm (28-33 in.lbs.)] is applied to the drive pinion.
CAUTION: If the drive gear is rotated too much, the tooth contact pattern will become unclear and
difficult to check.
Torque 1.5 ft.lb

Page 4994
Page 4598
A. Roller bearing installation. (3)
1. Select a snap ring that adjusts the end play of the counter shaft gear roller bearing to the
standard value shown below.
C. Ball bearing installation. (1)

Page 6649

Page 2683
reprogramming.

Page 4027
the arrow.

Page 7031
Wire Color Codes
the marking color.

Page 3002

Page 3121
EGR Control Solenoid: Description and Operation
OPERATION
- THE EGR solenoid is a duty control type solenoid. It makes control by leaking EGR valve
operating negative pressure to the throttle body A port.
- Power supply from the battery is sent through the MFI relay to the EGR solenoid. When the
engine control module turns off the power transistor inside the module, current no longer flows
through the coil and EGR valve operating negative pressure leaks.
Page 635
Standard value:
oxygen sensor.
Page 5374
Wire Color Codes
the marking color.

Page 3593


Page 2247

Page 2446
INSPECTION
Using Scan Tool

Page 471

Page 2404

Page 2303

Page 5823

Page 6757
The cost for the odometer resetting will be billed to your dealership. For reimbursement when the
speedometer is covered under the vehicle warranty, this expense can be claimed as a sublet repair
along with the labor removing and replacing the unit and the shipping. Refer to warranty bulletin
WB 2001-012.
This bulletin is for information only, not warranty authorization. For complete warranty information
concerning new speedometer odometer resetting, see Warranty Bulletin WB 2001-012. If you have
any questions regarding this service or the procedures, please contact the Warranty Hotline at
800-380-2324.
Page 1594
Wire Color Codes
the marking color.

Page 6241
Headliner Repair Nature Code: 86Z
Cause Code: 440
Labor Operation No. 52410100 Time Allowance: 1.0 hrs.
Warranty Coverage: 3 years/36,000 miles. Special Warranty Information: Normal warranty

procedures apply.
Page 3526
Grounding Markings

Page 707
Wire Color Codes
the marking color.

Speaker: All Technical Service Bulletins Audio System - Speaker Static/Buzzing/Inoperative
PURPOSE
Symptom/Condition
^ Static
^ Popping
^ Crackle
^ Buzzing
^ Rattle
^ Distorted sound
CHECKLIST REQUIRED
AFFECTED VEHICLES
PROCEDURE
Page 1227
INSPECTION
INSTALLATION
Page 6974
Key Cylinder Lamp: Testing and Inspection
Key Hole Illumination Light Timer Check
1. Apply battery positive voltage between terminal 2 and terminal 4. 2. Connect a test light between
terminal 1 and terminal 4. 3. Check that the test light illuminates for 8-16 seconds when terminal 3
is grounded for 3 seconds or more and then disconnected from the ground.
Page 3560
23, D3 - 10)
Page 4924
Parking Brake Shoe: Service and Repair
REPLACEMENT
1. Remove the rear brake assembly. 2. Remove the rear disc/rotor. 3. Remove the adjuster wheel
spring. 4. Remove the shoe hold-down cup, pin and adjuster. 5. Remove the anchor-to-shoe
springs, strut and strut-to-shoe spring. 6. Remove the clip and the shoe/lining assembly. 7.
Reverse procedure to install, noting the following:
- The load on the respective anchor-to-shoe springs is different, so the spring indicated by the
arrow has been painted for identification.
Page 1913
database number.
Page 1595
Multi Meter
Specifications
...................................................................... 1.12 W
Service and Repair
Page 4648

Page 5885
3. Place three old tires, without wheels, on top of the tire secured to the air bag module, and secure
all tires with ropes (4 locations). 4. At a location as far away from the air bag module as possible,
and from a shielded position, if possible, disconnect the two connected wires
from each other and connect them to the two terminals of the battery (removed from the vehicle) to
deploy the air bag.
CAUTION: 1. Before deployment, check carefully to be sure that no one is nearby. 2. The inflator
will be quite hot immediately following deployment, so wait at least 30 minutes to allow it to cool
before attempting to handle
it. Although not poisonous, do not inhale gas from air bag deployment. See Deployed Air Bag
Module Disposal Procedures (as shown below) for post-deployment handling instructions.
3. If the air bag module fails to deploy when the procedures above are followed, do not go near the
module. Contact your local distributor.
5. Dispose of the air bag module after deployment according to the Deployed Air Bag Module
Disposal Procedures.
DEPLOYED AIR BAG MODULE DISPOSAL
After deployment, the air bag module should be disposed of in the same manner as any other
scrap parts, except that the following points should be carefully noted during disposal. 1. The
inflator will be quite hot immediately following deployment, so wait at least 30 minutes to allow it to
cool before attempting to handle it. 2. Do not put water or oil on the air bag after deployment. 3.
There may be, adhered to the deployed air bag module, material that could irritate the eyes and/or
skin, so wear gloves and safety glasses when
handling a deployed air bag module.
CAUTION: If despite these precautions, the material does, get into the eyes or on the skin,
immediately rinse the affected area with a large amount of clean water. if any irritation develops,
seek medical attention.
4. Tightly seal the air bag module in a strong vinyl bag for disposal. 5. Be sure to always wash your
hands after completing this operation.
Page 6195
NOTE:
WARNING:
NOTE:
Page 7067
on actual vehicles.
Wire Color Codes
Page 6369
Page 6826
Backup Lamp: Testing and Inspection Manual Transmission
The back-up lights do not illuminate. -
Check the back-up light switch.
- Check the back-up light bulb.

NOTE: -
(A1 - Ground)
(A2 - 88)
Page 7119

Page 5325
Power Steering Pump: Fluid Type Specifications
Automatic Transmission Fluid "DEXRON II" used for flow control valve, friction surface of rotor,
vane, cam ring, pump cover and O-ring.

Page 2520
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Page 4154
are matched.
Page 6852
Grounding Markings

Removal and Replacement
Drive/Propeller Shaft: Removal and Replacement
REMOVAL
A. Rear propeller shaft/front propeller shaft removal. (1 & 2)
1. Make mating marks on the flange yoke and the differential companion flange.
Specifications
Charge Lamp/Indicator: Specifications
Charge warning light ............................................................................................................................
...................................................................... 1.12 W
Seat Latch: Recalls Recall - Rear Cargo Mat
NO: SR-98-004
DATE: October, 1998
PURPOSE
Remedy
area mat
NOTE:
Page 3881
Fluid Pan: Fluid Type Specifications
SEALANTS
Mitsubishi genuine sealant Part No. MR166584 or equivalent.

Page 4213
dimensions from the pressure ring rear face to the thrust washer end face is at the standard value.
Standard value: 0.05 mm (0.0020 inch) or less
NOTE: Measure the distance while squeezing the V-shaped groove manually.
11. Place each part in differential case (B) as shown in the illustration.
NOTE: Be careful not to insert the friction plates and friction discs in the incorrect order or install
the spring plates in the incorrect direction.
B. Screw installation. (1)
1. Align the mating marks (the same numeral on each case) of differential case (A) and differential
case (B).
2. Turn the screwdriver slowly several times to tighten the screw so that the cases are in close
contact.
NOTE: If the end surfaces of differential case (A) and differential case (B) do not come into close
contact even though the screw is tightened, the thrust washer and the spring plate are probably not
fitting into the groove correctly, so repeat the reassembly procedure.
3. After assembly, use the special tools to measure the starting torque in order to check the
frictional force of the clutch plate.
Standard value:
When a new clutch plate is used: 40-50 Nm (29-54 ft. lbs.) When an old clutch plate is used: 25-75
Nm (18-54 ft. lbs.)
NOTE: Measure the starting torque after rotating the clutch plate slightly. When measuring the
torque, do so at the beginning of movement.
Page 3822
Clutch: Diagrams
Page 1392
Inspection
switch.
Continuity Check
Page 3891
B. Seal ring installation. (2)

Page 1742
Page 2128
SENSOR VIEW

Page 600
Grounding Markings

Cargo Door
Rear Door Exterior Handle: Service and Repair Cargo Door
BACK DOOR HANDLE AND LATCH
Removal steps
• Back door trim and waterproof film
• Door outside handle play check
1. License plate light garnish
2. Door outside handle
3. Back door latch assembly
4. Back door lock actuator
5. Retainer
6. Back door key cylinder

Page 622

Page 3836
Page 1580
- Tighten the intake manifold mounting nuts one bank after the other by the following procedure. a.
Tighten the nuts in the right bank to 7 Nm (5 ft. lbs.). b. Tighten the nuts in the left bank to 20 - 23
Nm (14 - 17 ft. lbs.). c. Tighten the nuts in the right bank to 20 - 23 Nm (14 - 17 ft. lbs.). d. Repeat
steps b and c one more time respectively.
Page 5164
Dedicated Fuse
Page 517
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Page 1791
Sensor .................................................................................................................................................
........................................ 10 - 12 Nm (7 - 9 ft. lbs.)
Page 4087
Correction
PURPOSE
AFFECTED VEHICLES
PROCEDURE
NOTE:
Service and Repair
Page 4566
on actual vehicles.
Wire Color Codes
Specifications
King Pin: Specifications
Inclination ............................................................................................................................................
....................................................................... 14° 52'
Main Bearing Clearance, Standards and Limits
Crankshaft Main Bearing: Specifications
Journal Oil Clerance Standard 0.02-0.04 mm
Limit 0.1 mm
Bearing Size Codes Chart

Page 1039
Drive Belt: Adjustments Power Steering
DRIVE BELT TENSION
shown.
Standard value:
c. Adjusting belt tension with adjusting bolt.

Page 421
on actual vehicles.
Wire Color Codes
Page 2877
on actual vehicles.
Wire Color Codes
Page 2710
Specifications
Planetary Gears: Specifications
Front Planetary Ring Gear Bushing Inner Diameter:
Limit .....................................................................................................................................................
................................... 24.07 mm (0.948 inch)
Page 7066


Page 2130
SENSOR VIEW

Page 687
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A1 - 92)
control module. -
Page 3981
Specifications
Canister Purge Solenoid: Specifications Solenoid Resistance
Solenoid Resistance

Page 3313
Page 3072
Spark Plug Cable

Locations
Page 2209

Battery Charging
Battery: Description and Operation Battery Charging
CAUTION: When batteries are being charged, an explosive gas forms beneath the cover of each
cell. Do not smoke near batteries on charge or which have recently been charged. Do not break
live circuits at the terminals of the batteries on charge. A spark will occur where the live circuit is
broken. Keep all open flames away from the battery.
Battery electrolyte temperature may temporarily be allowed to rise to 55°C (131°F)
Increase of electrolyte temperature above 55°C (131°F) is harmful to the battery, causing
deformation of battery cell, decrease in life of battery, etc. If the test indicator is white, the battery
should be charged as outlined below. When the dot appears or when the maximum charge shown
below is reached, charging should be stopped.
Page 3961

Federal
Canister Purge Solenoid: Description and Operation Federal
OPERATION
- The evaporative emission purge solenoid is a duty control type of solenoid; it functions to regulate
the introduction of purge air from the evaporative emission canister to the intake manifold plenum.
- Battery positive voltage is supplied, by way of the MFI relay, to the evaporative emission purge
solenoid. When the engine control module switches on the ignition power transistor within the unit,
current flows to the coil, and purge air is introduced.
Page 6999


Page 4758

Page 6493
on actual vehicles.
Wire Color Codes
Page 1211
Tires: Component Tests and General Diagnostics
Tire Inflation Pressure Check
Check the inflation pressure of the tires. If it is not within the standard value, adjust it.
NOTE: Refer to the inflation pressure label on the driver's side.
Tire Wear Check
1. Measure the tread depth of tires.
2. If the remaining tread depth is less than the limit, replace the tire.
NOTE: When the tread depth of tires is reduced to 1.6 mm (.06 inch) or less, wear indicators will
appear.
Page 3596
Page 2287
Wire Color Codes
the marking color.

Page 3666
Part 2 Of 3
Page 6611
For Front Seat
Auxiliary Power Outlet: Service and Repair For Front Seat
Removal
Installation

Page 4961
(Part 1 Of 2)
Specifications
Camshaft Gear/Sprocket: Specifications
Mounting Bolt .......................................................................................................................................

.............................................. 88 Nm (65 ft. lbs.)
Page 4987
Page 229

Page 4404
Wire Color Codes
the marking color.

Page 6740

Locations

Page 721


Page 5165
Centralized Relay
Wheel Speed Sensor
Page 5558

Service and Repair
Parking Brake Cable: Service and Repair
REPLACEMENT
1. Remove the rear brake assembly. 2. Remove the rear brake disc. 3. Remove the adjusting
wheel spring, shoe hold-down cup and pin. 4. Remove the adjuster and anchor to shoe spring. 5.
Remove the strut and the strut-to-shoe spring. 6. Remove the shoe and lining assembly. 7.
Remove the heat protector and the parking brake cable. 8. Reverse procedure to install, noting the
following:
Page 4349
3. Use the special tool to press the opposite side journal bearing into the yoke.
CAUTION: Be careful when pressing the journal bearings, as if they are pressed at an angle, the
inside of the journal bearings will be damaged by the journal.
4. Align the mating marks on the yoke and propeller shaft and install the propeller shaft journal
bearings in the method described in steps 2
and 3 above.
1. Install a snap ring to one side of the journal.
2. Use the special tool at the opposite side of the installed snap ring to press in the journal bearing
toward the snap ring.
Page 2853


Exterior Moulding / Trim: All Technical Service Bulletins Wind Noise At Upper Windshield
PURPOSE
AFFECTED VEHICLES
1992-97 Montero
PROCEDURE

Locations
Number One Cylinder
Page 6842
Brake Lamp: Testing and Inspection
1. The stop lights do not illuminate.
- Check the stop light switch.
- Check multi-purpose fuse No. 17.
2. Either stop light does not illuminate.
3. The stop lights do not illuminate.
- Check the stop light switch.

Page 6462
Wire Color Codes
the marking color.

Specifications

............................................... 12 Nm (9 ft. lbs.)
Page 7035
Parking Lamp: Testing and Inspection
and Inspection
- Check the bulb.

Page 7126
Vanity Lamp: Description and Operation
- When the lid of the vanity mirror is opened, the vanity mirror light switch is set to the ON position,
the vanity mirror light illuminates.
Page 902
Wire Color Codes
the marking color.

Front Combination Light
Marker Lamp: Specifications Front Combination Light
Front side marker light .........................................................................................................................
........................................................... 27/8 (1157) W

Page 3078
Canister Purge Solenoid: Electrical Diagrams
A/T - V4AW3 Forward Clutch Piston Stroke Revisions
Clutch: Technical Service Bulletins A/T - V4AW3 Forward Clutch Piston Stroke Revisions
NO.: TSB-98-23-O11 DATE: July, 1998 MODEL: See Below
SUBJECT: FORWARD CLUTCH PISTON RELATED REVISIONS (V4AW3 A/T) - SERVICE

MANUAL REVISION
PURPOSE This bulletin contains corrections to the forward clutch piston stroke specifications for
the 1996 Montero and new special tool information relating to the forward clutch piston for all
1996-98 Montero and 1997-98 Montero Sport.
AFFECTED SERVICE MANUALS Automatic Transmission Overhaul Service Manual, Pages

23F-6, 23F-13, 23F-58 1996 Montero Service Manual, Volume 1, Pages 23C-6, 23C-14, 23C-58
1997 & 1998 Montero Service Manuals, Volume 1, Pages 23B-13, 23B-57 1997 & 1998 Montero
Sport Service Manuals, Volume 1, Pages 23B-6, 23B-55

Page 669
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A2 - 87)
- 92)
Page 5577
2. When installing the torsion bar, align the white mark on the serrated section of the torsion bar
with the mating mark on the anchor arm.
b. Anchor collar installation (3).
Install the anchor collar with the slit downward.
c. Bump stopper and bump stopper bracket clearance adjustment (-).
1. Tighten the adjusting nut until the protruding length of the anchor bolt is 80 mm (3.15 inch) or
less.
2. With the vehicle in an unladen condition, measure the distance from the bump stopper to the
bump stopper bracket to check if it is at the
standard value. Standard value: 21-23 mm (.83-.91 inch)
3. If outside the standard value, adjust the anchor bolt with the adjusting nut.
Page 2704
Specifications
.................................................................... 1.12 W
Page 1460
Drive Belt: Specifications Power Steering
When checked
..............................................................................................................................................................
13.8 - 17.8 mm (0.54 - 0.70 inch) When new belt is installed
............................................................................................................................................ 10.7 -
......................................................................................................................................... 14.8 - 16.8
mm (0.58 - 0.66 inch)
TENSION
When checked .....................................................................................................................................

.................................................................................................................................................... 490 -
...................................................................................................................................................... 343
- 441 N (77 - 99 lbs.)
NOTE: Apply 98 N (22 lbs.) force to the belt back midway between the pulleys, measure the
amount of deflection.
Fixing Nut ............................................................................................................................................

................................. 9.8 - 19.6 Nm (7 - 14 ft.lbs.)
Page 7013

Page 3411
1996 Montero, 3.0L 24 Valve Engine (DOHC)

Page 5435
1992-95 Montero Service Manual, Volume 1, page 37A-22
Page 4704
Page 2063
OPERATION
Page 1192
Maintenance Required Lamp/Indicator: Service and Repair
The OEM does not provide a Maintenance Required Indicator for this model.
Page 5324
Power Steering Pump: Pressure, Vacuum and Temperature Specifications
Oil Pump Pressure
Relief ...................................................................................................................................................
....................... 8.31 - 9.00 MPa (1,205 - 1,305 psi) Under No-load Conditions
................................................................................................................................................ 0.78 -
0.98 MPa (114 - 142 psi) Steering Gear Retention Hydraulic
............................................................................................................................. 8.31 - 9.00 MPa
(1,205 - 1,305 psi)
Page 4988

Page 2024
OPERATION
ground.
Page 2218
Wire Color Codes
the marking color.

Page 1559

Radio/Stereo: Diagram Information and Instructions
Page 4407
INSPECTION
measurements

Page 3299
on actual vehicles.
Wire Color Codes
Reconditioning Procedure
Valve Seat: Service and Repair Reconditioning Procedure
1. Before correcting the valve seat, check for clearance between the valve guide and valve and, if
necessary, replace the valve guide. 2. Using the seat grinder, correct to obtain the specified seat
width and angle. 3. After correction, valve and valve seat should be lapped with a lapping
compound. Then, check the valve stem projection.

Switch Adjustment
V4AW2 A/T.
23A-45
Page 4809


Page 6816
Grounding Markings

NO.: TSB-95-16-003
MODEL: All Models
VEHICLES AFFECTED
All models
PROCEDURE
CAUTION:

Page 5426
Tie Rod End: Service and Repair
STEERING LINKAGE
REMOVAL

Page 4685
Grounding Markings

Page 75
RELAY VIEW

Page 5389
b. Side cover and cross-shaft assembly removal (4).
With the mainshaft and cross-shaft placed in the straight-ahead position, tap the bottom of the
cross-shaft with a plastic hammer to take out the cross-shaft together with the side cover.
c. Y-Packing removal (10).
Do not remove the Y-packing at the rear of the needle bearing unless there is fluid leakage from
the threads of the adjusting bolt. If there is leakage, replace the Y-packing with a new one.
d. Rack piston removal (13).
Remove the rack piston from the mainshaft by turning it counterclockwise.
CAUTION: Be careful not to lose the 26 balls inside the rack piston.
e. Lock nut removal (19).
f. Main shaft/bearing race/cage/ball removal (20, 21, 22 & 23). When removing the main shaft,
remove it while pressing the bearing race so that the balls do not come out.
Specifications
Brake Pedal Assy: Specifications
DIMENSIONS
Pedal to Floor Clearance .....................................................................................................................

................................................ 100 mm (3.94 inch) Free Play ............................................................
......................................................................................................................... 3-8 mm (0.12-0.31
inch) Pedal Height ...............................................................................................................................
............................................ 186-191 mm (7.3-7.5 inch.)
Bracket To Frame Nut .........................................................................................................................

................................................. 14 Nm (10 ft. lbs.) Bracket To Frame Bolt .........................................
................................................................................................................................ 22 Nm (16 ft. lbs.)
Pedal Support Bushing Nut .................................................................................................................
................................................. 29 Nm (22 ft. lbs.) Shift Lock Cable Nut ............................................
................................................................................................................................. 12 Nm (9 ft. lbs.)
Page 3521
Ignition Coil: Locations

Overhaul
Brake Caliper: Service and Repair Overhaul
Front
Page 6822
Back-Up Light
Page 6612
Low Fuel Lamp/Indicator: Description and Operation
- This warning light illuminates when the fuel in the fuel tank falls less than approx. 11 cubic
decimeter (2.9 gals.)
Radio/Stereo: All Technical Service Bulletins Audio System - Speaker Static/Buzzing/Inoperative
PURPOSE
Symptom/Condition
^ Static
^ Popping
^ Crackle
^ Buzzing
^ Rattle
^ Distorted sound
CHECKLIST REQUIRED
AFFECTED VEHICLES
PROCEDURE
Page 2408
on actual vehicles.
Wire Color Codes
Page 905
Ignition switch-ST
HARNESS INSPECTION
module. -
NOTE: -

Page 5532
AFFECTED VEHICLES
1995-99 Montero
PROCEDURE

Page 4229

Page 2005
on actual vehicles.
Wire Color Codes
Page 1767
Grounding Markings

Page 2746
Wire Color Codes
the marking color.

Page 914
Page 762
pushed.

malfunction.
Page 6662

Page 322

Specifications
At 20° C (68° F) ...................................................................................................................................

................................................... 36 - 46 ohms
Page 4709
PARTS INFORMATION
Page 661
Grounding Markings

Page 4415
COMPONENT VIEW

Page 3539
examples 1 and 2.)
low.

Page 2761
on actual vehicles.
Wire Color Codes
Page 6461
on actual vehicles.
Wire Color Codes
Page 5441
1992-95 Montero Service Manual Volume 1, page 37A-41

Page 5319
2. Connect the pressure hose so that its slit part contacts the oil pump guide bracket.
NOTE: Operational steps after installation as follows: 1. Fill power steering fluid. 2. Bleed Power
steering fluid line. See: Service and Repair
Page 1946
Page 4564

Page 638
Standard value:
oxygen sensor.
Locations

Front Axle
Universal Joint: Specifications Front Axle

.......................................... 11 mm (0.43 inch)
Specifications
.................................................................... 1.12 W
Page 1203
Tires: Technical Service Bulletins Snow Tire - Recommendations
NO.: TSB-97-31-001 DATE: January, 1997 MODEL: All 1997 Models
SUBECT: SNOW TIRE RECOMMENDATIONS
PURPOSE Snow tires are available for most 1997 models. This bulletin lists recommended
Michelin and Yokohama snow tires for these vehicles.
Snow tires are not available from Michelin and Yokohama for the following models:
1997 Eclipse GSX 1997 Montero SR 1997 Montero Sport 1997 3000GT SL and VR4
NOTE:
Refer to TSB-97-31-003 REV, issued 12/96, for tire chain recommendations for all 1997 models.
For further snow tire information, contact your local Michelin or Yokohama tire dealer or their
national office at:
Michelin (800) 847-3435 Yokohama (800) 423-5444
AFFECTED VEHICLES
All 1997 models
SERVICE INFORMATION
Refer to the Snow Tire table in this bulletin. Remember that speedometer readings with snow tires
installed sometimes vary slightly from speedometer readings with standard tires.
When snow tires are used, they must be installed on all four wheels. Do not mix and match tire
types.

SRS Maintenance
them with new ones.
A. WARNING
injury.
Specifications
At 20° C (68° F) ...................................................................................................................................

................................................... 36 - 46 ohms
Page 2042


Page 6702
on actual vehicles.
Wire Color Codes
Page 4259
CONTROL UNIT VIEW
Spark Plug Cable

Instruments - Odometer Reset After Replacing
Speedometer
Speedometer Head: Technical Service Bulletins Instruments - Odometer Reset After Replacing
Speedometer
NO.: TSB-06-54-011
DATE: December, 2006
MODEL: All except Raider

SUBJECT: SPEEDOMETER REPLACEMENT & ODOMETER RESETTING TO ACTUAL
MILEAGE
This bulletin supercedes TSB-01-54-006, to update SPECMO's address. Revisions and indicated
by <.
PURPOSE
This bulletin contains instructions for having the odometer on a newly replaced speedometer reset
to the actual vehicle mileage.
AFFECTED VEHICLES All except Raider
PROCEDURE
To administer this program, contact Specmo Enterprises, Inc. Contact information is shown. Ship
the new speedometer head/cluster along with the speedometer being replaced to Specmo at the
address listed. You must include the old speedometer so Specmo's repair facility can verify the
actual recorded mileage. The repair facility will reset the new speedometer's odometer to the actual
mileage indicated. Specmo will return BOTH units to your dealership via overnight shipment.
NOTE:
Retain the old speedometer head/cluster for the normal parts retention period.
PARTS INFORMATION
Page 2267
on actual vehicles.
Wire Color Codes
Page 3033
Ignition switch-ST
HARNESS INSPECTION
module. -
NOTE: -

Page 3592

Locations

Page 2327
Page 680
Grounding Markings

Page 5402
statement as shown.
Page 5535
NOTE:
Page 5866
1992-96 Diamante Service Manual, Volume 1, Page 52B-31 Add the new SRS troubleshooting
Locations

Page 2705
Page 4632
Part 2 Of 3
Page 6421
Locations

Page 5147


Application and ID
Page 6164
Note: Listed are symbols used on the table.
A slash (/) in the Material Symbol column indicates that two different materials make up a
co-polymer, while a plus (+) in this column indicates blended materials.
# Indicates there may be a difference in heat resistance temperature depending on the ratio
between the mixed materials.
* Indicates this material cannot be measured because they are made of foam as well as double
laminated materials.
Paint - Exterior Color Codes and Applications
Paint: Technical Service Bulletins Paint - Exterior Color Codes and Applications
NO.: TSB-98-51-001
DATE: September, 1996
MODEL: All 1997 Models
SUBJECT: EXTERIOR COLOR CODES AND APPLICATIONS
PURPOSE
This bulletin contains complete exterior color information on all 1997 Mitsubishi Motors vehicles.
The tables are as follows:

Page 5629

Page 1302
NOTE
CAUTION
operation.
CAUTION
rocker arm.
NOTE
1. Stop the engine.
Page 4365
Page 5978
terminals.
INSPECTION
Page 1655
8. Using a crankshaft spacer tool No. MD998769, or equivalent, rotate the crankshaft a quarter of a
turn counterclockwise. Then rotate it
back clockwise to verify that all the timing marks are in alignment.
9. Install a torque wrench and tension pulley wrench tool No. MD998767, or equivalents, on the
tensioner pulley.
10. Torque it to 4.4 Nm (3.3 ft. lbs.) with the torque wrench. 11. While holding the tensioner pulley
in position, tighten the center bolt to 48 Nm (36 ft. lbs.). 12. Rotate the crankshaft two turns
clockwise and let it stand for approximately 5 minutes.
13. Check to see whether the metal wire inserted when the auto tensioner was installed can be
removed without any resistance.
NOTE: If the metal wire can be removed without any resistance, it means that the belt is correctly
tensioned. Therefore, remove the metal wire. In this condition, check that the projection of the rod
of the auto tensioner is within the standard value of 3.8 - 5.0 mm (0.150 - 0.196 inch).
14. If the metal wire cannot be removed easily, repeat steps, 9 through 12, until correct belt tension
is obtained.
Page 4533
transfer case.
transfer case.

transfer case.

Page 1165
Wire Color Codes
the marking color.

Page 1612

Specifications
Pitman Arm: Specifications
Pitman Arm Ball Joint Breakaway Torque
................................................................................................................................ 1 - 3 Nm (9 - 26
inch lbs.)
Page 3699
Wire Color Codes
the marking color.

Fluid - A/T: Capacity Specifications
Automatic Transmission Fluid Capacity
Capacity................................................................................................................................................
........................................................................ 8.9 Qt.
Page 1337
Connecting Rod: Service and Repair
REPLACEMENT
Refer to the illustration for the service procedure, noting the following:
Page 5657
>A< AIR SELECTION CONTROL WIRE INSTALLATION
Connect the air selection control wire to the air selection damper lever by following the steps below.
1. Move the air selection control lever to the recirculation position. 2. With the air selection damper
lever pressed inward in the direction indicated by the arrow, connect the inner cable of the air
selection control
wire to the end of the air selection lever and then use a clip to secure the outer cable.
INSPECTION
- Check for bending or abnormal deflection of the rotating shaft of the blower motor assembly.
- Check for damage to the fan.
- Check for damage to the blower case.
- Check the operation of the inside/outside air selection damper and check for damage.
BLOWER MOTOR ASSEMBLY
1. Connect the blower motor terminals directly to the battery and check that the blower motor
operates smoothly. 2. Next, reverse the polarity and check that the blower motor operates smoothly
in the reverse direction.
Page 1808
Radiator: Testing and Inspection
- Check for foreign material between radiator fins.
- Check the radiator fins for bend or damage.
- Check the radiator for corrosion, damage, rust or scaling.
- Check the radiator hoses for cracks, damage or deterioration.
- Check the reserve tank for damage.
- Check the spring of radiator cap for deterioration.
- Check the packing of radiator cap for damage or cracks.

Canister Purge Solenoid: Diagram Information and Instructions

Switch Adjustment
V4AW2 A/T.
23A-45
Page 3361
HARNESS INSPECTION
NOTE: -
- 92)
control module. -
(A3 - 90, A7 - 19)

Replacement

REMOVAL

Page 2894
Component View
Specifications
Oil Pick Up/Strainer: Specifications
M6 ........................................................................................................................................................
................................................... 9 Nm (7 ft. lbs.) M8 ..........................................................................
............................................................................................................................. 19 Nm (14 ft. lbs.)
Page 357
Power Switch Check
Operations Check

Page 5884
1. Install nuts that are no longer needed to the four bolts on the rear side of the air bag module, and
tie on some thick wire to secure to the wheel. 2. Take the SRS air bag adaptor harness B that is
connected to the wires, pass it beneath the old tire wheel assembly, and connect it to the air bag
module.
3. Insert the air bag module into the wheel, and secure it with wires that are tied to the bolt holes,
the air bag should face upward.
CAUTION: Leave some space below the wheel for the adaptor harness. If there is no space, the
reaction when the air bag deploys could damage the adaptor harness.
4. Place three old tires, without wheels, on top of the tire secured to the air bag module.
Front Passenger's Side
1. Connect the deployment wires to the SRS air bag adapter harness A, pass it beneath the tire,
and wheel assembly, and connect it to the air bag
module.
2. Pass the thick wires into the hole of the air bag module bracket, and secure it to the wheel of the
old tire with wheel (4 locations), with the air
bag facing upwards.
CAUTION: 1. Leave some space below the wheel for the deployment wires.
If there is no space, the reaction of the air bag deployment could result in damage of the adaptor
harness.
2. While deployment takes place, do not have the connector of the SRS air bag adaptor harness A
inserted between the tires.
Throttle Body - Overhaul Procedure Revision
Throttle Body: Technical Service Bulletins Throttle Body - Overhaul Procedure Revision
NO.: TSB-97-11-006 DATE: May, 1997 MODEL: See below
SUBJECT: THROTTLE BODY PROCEDURES - SERVICE MANUAL REVISION
PURPOSE The throttle body procedures on the affected engine overhaul and service manual
pages do not include the fixed SAS and speed adjusting screw. This service bulletin contains
corrected throttle body disassembly and reassembly instructions.
AFFECTED VEHICLES 1992-96 3000GT, Diamante and Truck 1992-97 Montero
AFFECTED SERVICE MANUALS 1992-96 Engine Overhaul, pages 11E-53 through 11E-57 1996
Montero, Volume 1, page 13A-177 1997 Montero, Volume 1, page 13A-152
Page 2912
Grounding Markings

Page 4456

Page 1164
on actual vehicles.
Wire Color Codes
Auxiliary Power Outlet: Testing and Inspection Accessory Socket Relay Check
Accessory Socket Relay Check - Chart
1. Remove the accessory socket relay from the junction block. 2. Apply battery positive voltage to
Engine - Replacement Piston Selection
Piston: Technical Service Bulletins Engine - Replacement Piston Selection
No: TSB-02-11-003 DATE: June, 2002 MODEL: See below
SUBJECT: PISTON SELECTION PROCEDURE
PURPOSE
When replacing a piston, be sure to use a piston of the appropriate size. Based on the Cylinder
bore size mark stamped on the cylinder block, select an appropriate size replacement piston from
the table provided in this bulletin.
AFFECTED VEHICLES All models equipped with 4G1, 4G9, 4G6, or 6G7 engine
PROCEDURE
Use the table shown to select the appropriate size replacement piston.
Page 1534

Page 3866
Part 2 Of 3
Page 5517
side.

Page 738
on actual vehicles.
Wire Color Codes
Page 3292
Idle Speed/Throttle Actuator - Electronic: Locations
Component View
Idle Air Control Motor A

Page 6878
Center Mounted Brake Lamp: Service and Repair
High Mounted Stop Light - Removal And Installation
Removal
Installation

Page 5855
1997 Mirage, Volume 1, page 52B-5, and 1997 Mirage Technical Information Manual, Page 6-14
Page 5988
Page 1450
1997 Montero Service Manual, Volume 1, Pages 11B-32 Correct the cylinder head and valve
removal and installation illustration as shown.
Page 6353

Page 2250
Wire Color Codes
the marking color.

Page 646

Page 1652
Timing Belt: Service and Repair
REPLACEMENT
1. Refer to the illustration for the service procedure.
2. Mark the belt running direction for reference in reinstallation.
NOTE:
Page 4813
Page 4282
Page 4025
REMOVAL
INSPECTION
Page 6758
Speedometer Head: Specifications
Speedometer indicator error mph.........................................................................................................
.....................................................Standard values
40..........................................................................................................................................................
.........................................................................38 - 44
60..........................................................................................................................................................
.........................................................................57 - 66
80..........................................................................................................................................................
.........................................................................76 - 88
100........................................................................................................................................................
.......................................................................94 - 110
Page 3876
A. Hose E/hose D/return pipe B/feed pipe B installation. (12, 13, 14 & 15)
When connecting hoses to pipes with a stepped part, insert securely as far as the stepped part.
B. Return pipe A/feed pipe A/clamp installation. (4, 5 & 6)
1. Provisionally tighten the return pipe A and feed pipe A flare nuts to the transmission and transfer,
and after clamping the pipes with each
clamp, fully tighten the flare nuts. Also, tighten all of the clamps, starting with those that are the
closest to the transmission and transfer assembly.
2. When connecting the pipes to the hoses, insert securely as far as the stepped part.
C. Hose C/hose B/hose A installation. (1, 2 & 3)
When connecting the pipes to the hoses, insert securely as far as the stepped part.
1. Fill and bleed automatic transmission fluid. 2. Install under cover and under skid plate.
Page 5910
Dispose of the old one according to the specified procedure.
CAUTION Never attempt to measure the circuit resistance of the air bag module (squib) even if you
are using the specified tester. If the circuit resistance is measured with a tester, accidental air bag
deployment will result in serious personal injury. 1. Check pad cover for dents, cracks or
deformities. 2. Check the air bag module for dents, cracking or deformation. 3. Check hooks and
connectors for damage, terminals for deformities, and harness for binds. 4. Check air bag inflator
case for dents, cracks or deformities. 5. Install the air bag module on the steering wheel or dash to
check alignment.
Clock Spring
If, as result of the following checks, even one abnormal point is discovered, replace the clock
spring with a new one. 1. Check connectors and protective tube for damage, and terminals for
deformities. 2. Visually check the case for damage.
Clock Spring
3. Check for continuity between the No.1 connector of the clock spring and connectors No. 3 and 4
Clock: Diagram Information and Instructions
Page 5506

Page 5969
Page 666
Page 2236
OPERATION
Pin/Journal Oil Clearance (Feeler Gauge Method)
Crankshaft: Testing and Inspection Pin/Journal Oil Clearance (Feeler Gauge Method)
1. If the oil clearance exceeds the limit, replace the bearing, and crankshaft if necessary. 2.
Measure the outside diameter of the journals and the inside diameter of the crankshaft bearings. If
the difference between them (oil clearance)
exceeds the limit, replace the crankshaft bearing and, if necessary, crankshaft. Standard value:
0.02 - 0.04 mm (0.0008 - 0.0016 inch) Limit: 0.1 mm (.004 inch)
NOTE: Do not attempt an undersize machining of the crankshaft with special surface treatment.
This crankshaft can be identified by its dull gray appearance.
Page 3172
Wire Color Codes
the marking color.

Page 2762
Wire Color Codes
the marking color.

Page 1923
Wire Color Codes
the marking color.

Page 2099
on actual vehicles.
Wire Color Codes
Page 1243
injection.
CAUTION: -
100 kPa (14 psi).
NOTE: -
Page 3600
harness. (A3 - B1)
(A1 - Ground)
harness. (A2 - 89)
Page 2899

Page 741
OPERATION
Page 3277
Page 2843
increases.
INSPECTION
Using Scan Tool
HARNESS INSPECTION
- 92)
(A6 - 72)
Page 4689
Wire Color Codes
the marking color.

Page 4857
Drum Brake System: Vehicle Damage Warnings
CAUTION: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables or
electrical connectors. Brake fluid will damage paint and electrical connections. If any fluid is spilled
on the vehicle, flush the area with water to lessen the damage.
Specifications
Sensor Bolt
Torque 7 ft.lb
Page 2113


Windshield: All Technical Service Bulletins Wind Noise At Upper Windshield
PURPOSE
AFFECTED VEHICLES
1992-97 Montero
PROCEDURE

Page 509


Page 2686
reprogramming.
Specifications
Torque Converter: Specifications
Housing Clearance
.................................................................................................................................................. 31.1
mm or more (1.22 inch or more)
Converter Housing:
10 mm (0.39 inch) Diameter Bolt

................................................................................................................................................... 35
Nm (25 ft. lbs.) 12 mm (0.47 inch) Diameter Bolt
................................................................................................................................................... 58
Nm (42 ft. lbs.)
Page 4538
1. Select and install the snap ring which adjust the transfer input gear bearing end play to the
standard value.

Page 3955

Specifications

........................................... 35 Nm (26 ft. lbs.)
Page 7040
RELAY VIEW
Headlight Relay B
Tires: Mechanical Specifications
Tread Depth Of Tire:
Limit .....................................................................................................................................................
........................................... 1.6 mm (.06 inch)
Page 4458
Page 4400
Grounding Markings

Basic Idle Speed
readjustment.
procedure.
grounded.

Locations
Computers and Control Circuit Diode: Locations
COMPONENT VIEW
Diode (for MFI System Circuit) B

Page 1313
condition.
NOTE
CAUTION
Page 6534
Teck Line.
Page 1925
Page 3549
Measurement method
parts.
power transistor.

Page 5255


Switch Adjustment
V4AW2 A/T.
23A-45
Page 7079
Passing Switch
Passing Switch
Replacement
Shifter A/T: Service and Repair Replacement
Page 107
Centralized Relay
Page 1848
Page 6843
Brake Lamp: Service and Repair
Rear Combination Light - Removal And Installation
Removal
Installation

Page 586

Page 3305
STEP 2. Check for an open circuit or a short-circuit to ground between the idle air control motor
- Idle air control motor connector: Disconnected OK: STOP NG: Repair the harnesses. (A1 - 4, A3 -
17, A4 - 5, A6 - 18)
IDLE AIR CONTROL MOTOR CHECK Checking Operation Sound
(1) Check that the operating sound of the stepper motor can be heard over the idle air control
motor when the ignition switch is turned to the ON
position (without starting the engine).
(2) If no operating sound can be heard, check the stepper motor drive circuit. (If the circuit is good,
a defective stepper motor or engine control
module is suspected.)
Checking Coil Resistance
(1) Disconnect the idle air control motor connector and connect the special tool (test harness). (2)
Measure the resistance between terminal (2) (White clip of the special tool) of the connector at the
idle air control motor side and terminal (1)
(red clip) or terminal (3) (blue clip).
Standard value: 28 - 33 Ohms [at 20°C (68°F]
(3) Measure the resistance between terminal (5) (green clip of the special tool) of the connector sat
the idle air control motor side and terminal (6)
(yellow clip) or terminal (4) (black clip).
Standard value: 28 - 33 OHMS [at 20°C (68°F)

Page 1668
Page 6566
Fuel Gauge: Testing and Inspection Troubleshooting Hints
Fuel gauge does not operate or its operation is incorrect. -
Check the fuel gage.
- Check the fuel gage unit.

Page 1953

Page 5554
Suspension Strut / Shock Absorber: Locations

Page 3733
Hazard Light Switch

Page 782
harnesses.
Page 790

Page 6050

Page 1103
Power Steering Fluid: Fluid Type Specifications
ATF Dexron II
Page 4649
INSPECTION
measurements

Page 2234
Wire Color Codes
the marking color.

Page 6494
Wire Color Codes
the marking color.

Page 3364
- Example 2
normal.
Locations

SENSOR VIEW

Resistance/Torque

Page 5038
Battery: Specifications General Specifications
Items ....................................................................................................................................................
........................................................... Specifications
Type .....................................................................................................................................................
.............................................................. 75D26R-MF Ampere hours (5Hr) .........................................
............................................................................................................................................................
52 Ah Cranking rating [at - 18°C (0°F)] ...............................................................................................
.................................................................................. 490 A Reserve capacity min .............................
..............................................................................................................................................................
............ 123
NOTE:
1. CRANKING RATING is the current a battery can deliver for 30 seconds and maintain a terminal
voltage of 7.2 V or greater at a specified
temperature.
2. RESERVE CAPACITY RATING is the amount of time a battery can deliver 25 A and maintain a
minimum terminal voltage of 10.5 V at 27°C
(80°F).
Page 3331
Grounding Markings

Page 5350
Page 418
Grounding Markings

Page 1535


Page 2116
Page 5637
Lug Nut Torque Patterns

Page 920
Correction
PURPOSE
AFFECTED VEHICLES
PROCEDURE
NOTE:
Page 3899
Page 4874

Page 3802
Automatic Transmission Overhaul Service Manual, Page 23F-6: Change the forward clutch piston
Page 7086

Page 5592
INSPECTION
INSTALLATION
Specifications
Output Shaft: Specifications
End Play
..............................................................................................................................................................
0.27-0.86 mm (0.0106-0.0339 inch)
Page 6721

Page 1629
Crankshaft Main Bearing Seal: Testing and Inspection
1. Check the oil seal lip for wear and damage. 2. Check rubber for deterioration or hardening. 3.
Check the oil seal case for cracks and damage.
Replacement
Rear Knuckle: Service and Repair Replacement
REMOVAL
1. Remove front hub. 2. Follow removal steps outlined in illustration.
A. Tie rod assembly and knuckle disconnection. (3)
Use the special tool to disconnect the tie rod from the knuckle.
CAUTION: 1. Use a cord to bind the special tool closely so that it will not become separated. 2. The
nut should only be loosened, not removed.
Page 6247
RELAY VIEW
Door Lock Relay I

Page 3963

Page 2841
Page 6044
PARTS INFORMATION
Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications Coil Resistance
Coil Resistance

Page 954
Alignment: Testing and Inspection
1. Place the front wheels on turning radius gauge and measure steering angle.
Standard value:
Inside wheel: 29° 40' to 32° 40' Outside wheel: 29° 45'
2. If the steering angle is outside the standard value, check the toe-in, and then adjust the steering
angle with the stopper bolt.
Page 7008
Marker Lamp: Specifications Rear Combination Light
Rear side marker light .........................................................................................................................
.................................................................. 3 (168) cp

Page 1341
- Install the piston with the front mark (arrow mark) on the top of the piston directed towards the
engine front (timing belt side).
- Two types of pistons have been used, one for cylinders 1, 3 and 5 and the other for cylinders 2, 4
and 6. Pistons with an "R" are for cylinders 1, 3 and 5. Pistons with an "L" are for cylinders 2, 4 and
6.
20. Mate the correct bearing cap with the correct connecting rod by checking with the alignment
marks marked during disassembly. If a new
connecting rod is used which has no alignment mark, position the notches for locking the bearing
on the same side.
21. Check if the thrust clearance in the connecting rod big end is correct.
23. Loosely tighten each nut to the bolt. 24. Then tighten the nuts alternately to a torque of 34 Nm
(25 ft. lbs.) to install the cap properly. 25. Make a paint mark on the head of each nut. 26. Make a
paint mark on the bolt end at the position 90 - 100° from the paint mark made on the nut in the
direction of tightening the nut. 27. Give a 90 - 100° turn to the nut and make sure that the paint
mark on the nut and that on the bolt are in alignment.
CAUTION: -
Page 627
Wire Color Codes
the marking color.

Page 953
Alignment: Specifications
Measure distance between bump stop pad and bump stop bracket (B), or bump stop and bump
stop pad (A) as indicated in chart.
Measurment at Point A
Measurment 7/8 in.
22 mm
Page 3985
NOTE:
NOTE:
Page 446

Locations

Page 6079
Speaker: Service and Repair Door Speaker
Door Speaker - Removal And Installation
NOTE: * indicates that the speakers are installed on the right side also.
Removal
Installation

Page 494
on actual vehicles.
Wire Color Codes
Page 6184

Page 43
RELAY VIEW

Page 727
SENSOR CHECK
Page 6476
on actual vehicles.
Wire Color Codes
Page 2464
Door Lamp: Diagram Information and Instructions
Page 2133

Page 4680

Page 3484


Page 2679
check mark button.
VCI COMPONENTS
Page 1520
Oil Pan: Testing and Inspection
Check the oil pan for cracks. Check the sealant coated surface of the oil pan for damage and
deformation.
Page 4203
Differential Case: Specifications Limited Slip Differential
Clearance Between Spring Plate And Differential Case:
Standard Value ....................................................................................................................................

.................................... 0.06 mm (0.0020 inch)
Clearance Between Thrust Washer And Differential Case:
Standard Value ....................................................................................................................................

.................................... 0.05 mm (0.0020 inch)
Clutch Plate Preload:
When Equipped With New Clutch Plates

............................................................................................................................. 40-50 Nm (29-54 ft.
lbs) When Equipped With Old Clutch Plates
............................................................................................................................... 25-75 Nm (18-54
ft. lbs)
Difference In Total Thickness Between The Left And Right Clutch Plated:
Standard Value
.............................................................................................................................................................
0.05 mm (0.0020 inch) or less
Difference Between Left And Right dimensions From Back Thrust Face Of Pressure Ring To End
Of Thrust Washer:
Standard Value
.............................................................................................................................................................
0.05 mm (0.0020 inch) or less
Friction Plate And Friction Disc Warping:
Flatness (Limit) ....................................................................................................................................

...................................... 0.1 mm (0.0031 inch)
Friction Plate And Friction Disc Wear:
Difference In The Thickness Of The Friction Surfaces And The Projections:
Limit .....................................................................................................................................................
............................... 0.1 mm (0.0039 inch)
Specifications
Crankshaft Main Bearing Seal: Specifications
Mounting Bolts .....................................................................................................................................

................................................. 11 Nm (8 ft. lbs.)
Page 6357
on actual vehicles.
Wire Color Codes
Page 4264

Page 3384
Torque 1.5 ft.lb

Page 463

Page 1115
Refrigerant: Technical Service Bulletins Fluids, Refrigerants and Materials (Genuine Mitsubishi)
No: TSB-98-00-004 DATE: September, 1998 MODEL: All
SUBJECT: AUTHORIZED GENUINE MITSUBISHI FLUIDS, REFRIGERANTS, AND MATERIALS
The MMSA Parts Department recently introduced a new chemical program to provide your
dealership with a wide range of shop materials and car care products. Genuine Mitsubishi Fluids,
Refrigerants, and other materials are formulated especially for Mitsubishi vehicles. These are the
best products available to help Mitsubishi vehicles perform at their optimum performance level.
These Genuine Mitsubishi products offer advantages over aftermarket or generic brands when
used properly in Mitsubishi vehicles.
Genuine Mitsubishi Products offered (see PARTS INFORMATION section for part numbers):
^ Multi-purpose Cleaner/Degreaser ^ White Lithium Grease
^ Refrigerant (R12 & R134a) ^ Long-Life Coolant
^ Carburetor Cleaner ^ Brake Fluid
^ Brake Cleaner ^ Windshield Washer Fluid
^ Silicone Spray ^ Automatic Transmission Fluid (ATF SP II M)
TECHNICAL INFORMATION
Factory Fill Long Life Coolant Mitsubishi engineers have developed a superior, high-quality coolant
with advantages over the competition. This product is standard factory-fill and is now available for
service replacement. Most aftermarket coolants are designed for cast iron engines and in most
cases contain an inexpensive silicate additive to inhibit aluminum corrosion. Use of silicates can
cause water pump seal damage and radiator plugging. Therefore. silicate based antifreeze or
coolant is not acceptable for use in Mitsubishi vehicles. In contrast, Genuine Mitsubishi Coolant is
designed for modern aluminum alloy engines. It contains an organic corrosion inhibitor instead of
silicates. This formula has the following advantages:
^ Eliminates possible gelling which can cause radiator plugging and then overheating.
^ No silicate abrasion of water pump mechanical seals which causes leakage.
^ Corrosion protection for aluminum heat rejecting components.
^ Superior long-term corrosion protection for other cooling system metals including steel, cast iron,
copper, and solder.
Factory Fill Brake Fluid
Brakes are vital to automotive safety. Though often overlooked, brake fluid plays a significant role
in braking performance. To make sure that the brakes on Mitsubishi vehicles perform as designed,
Mitsubishi introduces Genuine Mitsubishi Brake Fluid - a superior product designed by Mitsubishi
engineers for Mitsubishi brake and hydraulic clutch systems. This is the same OEM factory fill fluid
currently used in all new Mitsubishi vehicles. Mitsubishi Brake fluid offers these advantages:
^ Higher wet boiling point (better than all other competitive brands tested).
^ Less water absorption
^ High Temperature stability
^ Does not form harmful sedimentation

Factory Fill Windshield Washer Fluid
This is the same, high-quality OEM factory fill fluid currently used in all new Mitsubishi vehicles.
This fluid is specially formulated for Mitsubishi vehicles for extended vehicle life and is the best
product available for Mitsubishi vehicles.
ATF SP II M (Automatic Transmission Fluid)
The 1999 Montero Sport automatic transmission must use new ATF SP II M rather than ATF SP II
or Dextron-II to ensure shift quality. Mitsubishi now has available a new ATF SP-II M transmission
fluid for use in these 1999 models. Mitsubishi ATF SP II M can also be used in, and is
recommended for any Mitsubishi vehicle which calls for ATF SP II or Dextron-II.
^ Specially formulated for use in all Mitsubishi automatic transmissions.

Specifications
Cargo Lamp: Specifications
Cargo space light .................................................................................................................................
.......................................................................... 10 W
Page 3044


Page 2161
on actual vehicles.
Wire Color Codes
Page 3843
Clutch: Service and Repair
Overdrive Clutch
DISASSEMBLY
INSPECTION
Page 1835
Page 2786
OPERATION
engine is cold.
Page 2118
INSPECTION
Using Scan Tool

HARNESS INSPECTION
harness. (A2 - 92)
(A1 - 74)
Engine - Using Low-Quality Engine Oil
Engine Oil: Technical Service Bulletins Engine - Using Low-Quality Engine Oil
SOURCE: Mitsubishi Tech Talk Article January/February 2005
TITLE: Using Low-Quality Engine Oil
SERVICE TIP:
It is very important that ONLY the recommended API SJ, API SL, or API SM engine oil be used in
Mitsubishi vehicles. Lower quality engine oils can seriously damage engine components (excessive
deposits, sludging, higher than normal component wear). Increased wear and deposits can also
lead to excessive emissions.
Customers should be instructed to use ONLY engine oil which meets the manufacturer's
requirements. Warranty coverage could be denied for failures attributed to improper engine oil
usage.
Page 367
Page 5370
Grounding Markings

Page 4240
REMOVAL
INSTALLATION
Page 5875
Change

REVISION
the new rotors.

Service and Repair
Removal
Installation

Page 634
(A4 - 79, B4 - 76, C4 - 73, D4 - 75)
(A3 - 42, 63 - 34, C3 - 43, D3 - 35)
D2 - 92)

Page 1340
14. When replacing the bearing, select the proper bearing according to the crankshaft identification
color and the connecting rod identification mark
and install it.
15. Liberally coat the circumference of the piston, piston ring, and oil ring with engine oil.
16. Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration. 17.
Rotate the crankshaft so that the crank pin is on the center of the cylinder bore. 18. Use suitable
thread protectors on the connecting rod bolts before inserting the piston and connecting rod
assembly into the cylinder block.
NOTE: Care must be taken not to nick the crank pin.
19. Using a suitable piston ring compressor tool, install the piston and connecting rod assembly
into the cylinder block.
NOTE:
Page 775
on actual vehicles.
Wire Color Codes
Page 2949

Page 5237
Alignment: Specifications
Measure distance between bump stop pad and bump stop bracket (B), or bump stop and bump
stop pad (A) as indicated in chart.
Measurment at Point A
Measurment 7/8 in.
22 mm
Page 6713
Grounding Markings

Page 2322
Grounding Markings

Page 3455

Page 2532
connector.
NOTE:
Removal and Installation
Intake Manifold: Service and Repair Removal and Installation
1. Relieve the residual pressure from the high pressure hose. Refer to Powertrain Mangement. 2.
Drain the engine coolant. 3. Remove the intake manifold plenum. 4. Refer to the illustration for
removal procedure. 5. Reverse procedure to install, noting the following:
- Install the gaskets with the projections in the position illustrated.
- Be sure to adjust the accelerator and throttle cable.

Page 393

Page 5998
Antenna Motor: Locations

Page 2440

Page 475
on actual vehicles.
Wire Color Codes
Specifications
ABS Light: Specifications
Anti-lock braking system warning light ................................................................................................
...................................................................... 1.12 W
Page 5962


Coil Spring Seat: All Technical Service Bulletins Differential Whine - Revision
PURPOSE
Symptom
Cause
Remedy
NOTE:
Page 1084
Fluid - Differential: Testing and Inspection Rear Axle
1. Remove the filler plug and check the oil level. 2. Check that the gear oil level is not 8 mm (.3 in.)
below the bottom of the filler plug hole.
Specified gear oil:
Conventional differential, Differential with rear differential lock: Hypoid gear oil API classification G
L-5 or higher SAE viscosity 80W.
Limited slip differential: Hypoid gear oil MITSUBISHI Genuine Gear Oil or equivalent.

Page 2870
SENSOR VIEW

Page 15
CONTROL UNIT VIEW
INSPECTION
Using Scan Tool
HARNESS INSPECTION
NOTE:
Page 3335
Wire Color Codes
the marking color.

Page 1723
c. If damp coolant residue or drips are seen, the water pump is defective and it must be replaced.
Refer to Group 14 - Cooling in the service manual for instructions.
WARRANTY INFORMATION This TSB provides information only.
Page 5771
12. Turn the vacuum pump adaptor switch to the R-134a side to start the vacuum pump.
CAUTION: Do not operate the air conditioning compressor to carry out evacuation.
13. Evacuate to a vacuum reading of 100 kPa (29.5 in.Hg) or higher (takes approx. 10 minutes).
14. Turn the vacuum pump adaptor switch OFF and allow to stand it for 5 minutes.
CAUTION: Do not operate the compressor in the vacuum condition, as damage may occur.
15. Carry out a leak test. (Good if the negative pressure does not drop.)
CAUTION: If the negative pressure is lost, check for loose connections. Then, repeat the
evacuation procedure from step 12. If the negative pressure is still lost, add 1 lb of refrigerant and
then use an R-134a compatible leak detector to check the system.
16. Turn the handle of the adaptor valve back all the way (valve closed), remove it from the gage
manifold and install the bulk container.
17. Open the valve of the bulk container. 18. Turn the handle of the charge valve back (valve open)
and tighten the handle of the adaptor valve (valve open) to charge the system with
refrigerant.
in gas state.
19. If the refrigerant is not drawn in, turn the handle of the adaptor valve back all the way (valve
closed). 20. Use a leak detector to check for gas leaks.
If a gas leak is detected, re-tighten the connections and then repeat the charging procedure from
evacuation in step (12).
CAUTION: A leak detector designed for R-134a should be used.

Page 5723
2. Drop or remove the glove box to gain access to the fan and duct assembly. On 1999-2003
Galants and 2000-2003 Eclipse with the A/C, heater, ventilation system filter, remove the filter
element.
NOTE:
The HVAC filter which must be removed was original equipment on 1999-2000 Galant and 2000
Eclipse. Be sure to check later models, also. This filter was a dealer installed option for 2001-03
Galant and Eclipse.
3. Set the A/C heater controls as follows:
^ Temperature control on HOT.
^ Fan on HI position
^ Air mode to RECIRC
^ Vent position to BI-LEVEL
4. Open all windows about 1/2 inch
5. Disconnect the air conditioner clutch electrical connection by removing the receiver/drier
pressure switch connector or by disconnecting the clutch connector at the compressor.
6. Place a protective cloth on the interior front carpet under the evaporator housing and duct. Start
the engine, letting it run at idle. As the engine idles with the heater controls set as instructed, hot air
recirculates over the evaporator raising the temperature of the evaporator, causing moisture to
evaporate faster. The open windows allow the moisture to escape without losing much heat. You
may see "fog" clouding the windows. After the fog disappears continue the operation for another 5
minutes. If the fog does not appear, continue with engine idling and the heater controls set for
another 30 minutes.
Specifications
Rated load ...........................................................................................................................................
............................................................... 6.6 ± 0.05 A Voltage drop ....................................................
.................................................................................................................................................. 0.2 V
or less
Page 6717
Wire Color Codes
the marking color.

Page 2595
Wire Color Codes
the marking color.

Page 6866

Page 84
RELAY VIEW
Headlight Relay B
Specifications
Fan Clutch: Specifications
Mounting Bolts .....................................................................................................................................

..................................... 10 - 12 Nm (7 - 9 ft. lbs.)
Page 1955
on actual vehicles.
Wire Color Codes
Page 6982

Page 2062
Page 245
COMPONENT VIEW

Page 3819
Page 1951

Specifications
Oil Cooler: Specifications
DIMENSIONS
By Pass Valve
Dimension (L): 34.5 mm (1.36 inch) By Pass Hole Closing Temperature [2]: 40 mm (1.57 inch) Or
More Oil Pressure At Curb Idle Speed [1]: 80 kPa (11.4 psi) Or More
Performance: 26,790 kJ/hr. (25,396 BTU/hr.)
[1] With the oil temperature at 75 - 90° C (167 - 194° F). [2] With the oil temperature at 97 - 103° C
(207 - 217° F) or more.
Page 5260
Grounding Markings

Page 5762
Refrigerant: Technical Service Bulletins Fluids, Refrigerants and Materials (Genuine Mitsubishi)
No: TSB-98-00-004 DATE: September, 1998 MODEL: All
SUBJECT: AUTHORIZED GENUINE MITSUBISHI FLUIDS, REFRIGERANTS, AND MATERIALS
The MMSA Parts Department recently introduced a new chemical program to provide your
dealership with a wide range of shop materials and car care products. Genuine Mitsubishi Fluids,
Refrigerants, and other materials are formulated especially for Mitsubishi vehicles. These are the
best products available to help Mitsubishi vehicles perform at their optimum performance level.
These Genuine Mitsubishi products offer advantages over aftermarket or generic brands when
used properly in Mitsubishi vehicles.
Genuine Mitsubishi Products offered (see PARTS INFORMATION section for part numbers):
^ Multi-purpose Cleaner/Degreaser ^ White Lithium Grease
^ Refrigerant (R12 & R134a) ^ Long-Life Coolant
^ Carburetor Cleaner ^ Brake Fluid
^ Brake Cleaner ^ Windshield Washer Fluid
^ Silicone Spray ^ Automatic Transmission Fluid (ATF SP II M)
TECHNICAL INFORMATION
Factory Fill Long Life Coolant Mitsubishi engineers have developed a superior, high-quality coolant
with advantages over the competition. This product is standard factory-fill and is now available for
service replacement. Most aftermarket coolants are designed for cast iron engines and in most
cases contain an inexpensive silicate additive to inhibit aluminum corrosion. Use of silicates can
cause water pump seal damage and radiator plugging. Therefore. silicate based antifreeze or
coolant is not acceptable for use in Mitsubishi vehicles. In contrast, Genuine Mitsubishi Coolant is
designed for modern aluminum alloy engines. It contains an organic corrosion inhibitor instead of
silicates. This formula has the following advantages:
^ Eliminates possible gelling which can cause radiator plugging and then overheating.
^ No silicate abrasion of water pump mechanical seals which causes leakage.
^ Corrosion protection for aluminum heat rejecting components.
^ Superior long-term corrosion protection for other cooling system metals including steel, cast iron,
copper, and solder.
Factory Fill Brake Fluid
Brakes are vital to automotive safety. Though often overlooked, brake fluid plays a significant role
in braking performance. To make sure that the brakes on Mitsubishi vehicles perform as designed,
Mitsubishi introduces Genuine Mitsubishi Brake Fluid - a superior product designed by Mitsubishi
engineers for Mitsubishi brake and hydraulic clutch systems. This is the same OEM factory fill fluid
currently used in all new Mitsubishi vehicles. Mitsubishi Brake fluid offers these advantages:
^ Higher wet boiling point (better than all other competitive brands tested).
^ Less water absorption
^ High Temperature stability
^ Does not form harmful sedimentation

Factory Fill Windshield Washer Fluid
This is the same, high-quality OEM factory fill fluid currently used in all new Mitsubishi vehicles.
This fluid is specially formulated for Mitsubishi vehicles for extended vehicle life and is the best
product available for Mitsubishi vehicles.
ATF SP II M (Automatic Transmission Fluid)
The 1999 Montero Sport automatic transmission must use new ATF SP II M rather than ATF SP II
or Dextron-II to ensure shift quality. Mitsubishi now has available a new ATF SP-II M transmission
fluid for use in these 1999 models. Mitsubishi ATF SP II M can also be used in, and is
recommended for any Mitsubishi vehicle which calls for ATF SP II or Dextron-II.
^ Specially formulated for use in all Mitsubishi automatic transmissions.

Page 4177
2. Apply multi-purpose grease to the contact surfaces of the companion flange oil seal and the
washer companion flange.
3. Install the drive pinion assembly and companion flange with the mating marks properly aligned,
and then use the special tools to
tighten the companion flange self-locking nut to the specified torque.
4. Use the special tools to measure the drive pinion rotation torque (with the oil seal) to confirm that
the drive pinion preload is at the
standard value.
Standard value:
New (with anti-rust agent): 0 5 - 0.7 Nm (4.3 - 6.1 inch lbs.) New/reused (gear oil applied): 0.35 -
0.45 Nm (3.1 - 3.9 inch lbs.)
5. If the measured value is not within the standard value range; check for incorrect installation of
the oil seal or incorrect tightening of the
self-locking nut.
E. Differential gear backlash adjustment. (-)
1. Assemble the side gears, side gear thrust spacers, pinion gears and pinion washers into the
differential case. 2. Provisionally install the pinion shaft.
NOTE: Do not drive in the lock pin yet.
3. Insert a wedge between the side gear and the pinion shaft to lock the side gear.
Removal and Replacement
Axle Shaft: Removal and Replacement
REMOVAL
1. Remove under cover. 2. Follow removal steps outlined in illustration.
A. Inner shaft removal. (4)
Attach the special tools to the flange of the shaft, and pull the inner shaft out from the front
differential carrier.
CAUTION: When pulling the inner shaft out from the front differential carrier, be careful that the
spline part of the inner shaft does not damage the oil seal.
INSPECTION
1. Check the inner shaft for bend. 2. Check the bearing for wear or discoloration. 3. Check the
housing tube for cracks.
Page 4559
COMPONENT VIEW

Disassembly and Reassembly
Throttle Body: Service and Repair Disassembly and Reassembly
Page 6106
CONTROL UNIT VIEW
Specifications
Front Hub:

.......................................................................................................................................... 0.05 mm
................................................................................................................................................. 0.3 -
1.3 Nm (2.6 - 11.3 inch lbs.)

.......................................................................................................................................................... 5
- 8 N (1.1 - 4.0 lbs.)
Specifications
Synchronizer Hub: Specifications
2-4WD Synchronizer Hub End Play

................................................................................................................................. 0-0.08 mm
(0-0.0031 inch)
Page 6298
CONTROL UNIT VIEW
Page 682


Locations

Page 1769


Page 2066
harness. (A3 - B1)
(A1 - Ground)
harness. (A2 - 89)
Page 6282
III. Two Tone Color Combinations.
Use these tables when ordering refinishing materials from your local automotive paint dealer.
1997 EXTERIOR COLORS
There are thirty eight colors included in the 1997 model line up. Twenty five colors are carried over
from previous years and thirteen colors are new. Also, there are eleven two tone exterior color
combinations.
Table II contains the manufacturers' stock numbers from several automotive refinish companies,
which correspond with the Color Codes and Applications shown in Table I.
The new colors for 1997 are identified by an asterisk (*)
Table III shows the two tone color combinations for 1997 models.
Diagrams
Joint Connector (J/C)

Armature Check
Starter Armature: Testing and Inspection Armature Check
Armature Short Circuit Test
1. Check the armature coil for short circuit. 2. Place armature in a growler. 3. Hold a thin steel
blade parallel and just above while rotating armature slowly in growler. A shorted armature will
cause blade to vibrate and be
attracted to the core. Replace shorted armature.
Armature Coil Grounding Test
4. Check the insulation between the armature coil cores and the commutator segments. They are
normal if there is no continuity.
Armature Coil Open Circuit Inspection
5. Check for continuity between segments. The condition is normal if there is continuity.
Page 2634
SENSOR VIEW

Page 2534
reprogramming.
Page 4285
4. Check the dust seal for cracks or damage.
INSTALLATION
A. Inner shaft installation. (4)
Drive the inner shaft into the front differential carrier by using the special tools (MB990241 and
MB990211).
CAUTION: Be careful not to damage the lip of the dust seal and oil seal.
NOTE: Operational steps after installation as follows: 1. Install under cover.

Page 157
relay as shown:
Page 4172
Assembly
Page 4311

Page 1423
Specifications
......................................................... Approx. 50 Ohm
Page 6902


Page 4085
Page 4806

INSPECTION
Page 7137
RELAY VIEW
Defogger Relay H
Page 6269

Page 2699
on actual vehicles.
Wire Color Codes
Page 6354
Grounding Markings

Page 921
NOTE:
NOTE:
Page 695
Page 2869

Page 6410
Cruise Control Servo: Locations For Federal
COMPONENT VIEW
Cruise Control Actuator (with built-in F
control valve and release valve)

Corrections
DTCs.
NOTE:

Page 2059


Page 1582
1. When removing the throttle body, leave the water hoses attached to the assembly. 2. Refer to
the illustration for removal procedure. 3. Reverse procedure to install, noting the following:
- Install with gasket protrusion in the position illustrated.
- Be sure to adjust the accelerator cable.

Page 234
Wire Color Codes
the marking color.

Front Suspension
Suspension Strut / Shock Absorber: Service and Repair Front Suspension
REMOVAL

Page 2796

Page 1792
Page 2672
the standard value.

the system.
Page 5228
Dedicated Fuse
Page 5373
on actual vehicles.
Wire Color Codes
Page 807

SENSOR VIEW

Page 3725
OPERATION
Page 1539

Specifications
Lock Up Solenoid ................................................................................................................................

............................................................................................................. 10 Nm (86.4 inch lbs.) Shift
Solenoid No. 2 .....................................................................................................................................
............................ 10 Nm (86.4 inch lbs.)
Page 4567
Wire Color Codes
the marking color.

Page 2308
OPERATION
ground.
Page 5375

Page 1987
Wire Color Codes
the marking color.

Page 4066

Page 2927

SENSOR VIEW

Page 4049
4. Continue flushing the cooler until only clear liquid comes from the outlet hose.
5. Reverse the hoses and flush in the other direction until only clear liquid comes from the hose.
For best results, use the entire contents of the aerosol can.
IMPORTANT
Clear liquid must flow freely in both directions through the oil cooler. If not, the oil cooler is clogged
with debris and must be replaced.
6. Turn the can upside down and blow any remaining liquid out of the cooler.
7. Verify that the flushing was adequate by performing the transmission cooler and auxiliary oil
cooler flow test described in TSB-98-23-004.
8. Reconnect the cooler hoses to the transmission and secure with clamps. Confirm that the hoses
are connected correctly to the inlet and outlet pipes of the transaxle.
8. Start the engine and check for leaks. With the A/T fluid temperature at normal operating
temperature (70-90° C or 158-194° F), check the automatic transmission fluid (ATF) level with the
engine idling and the transaxle in "Neutral."
9. Add ATF as necessary to bring the ATF level to the top of the "FULL" mark on the A/T dipstick.
10. Dispose of the waste solution in accordance with local, state, and Federal regulations.
PARTS INFORMATION
Page 3572

Page 5868
1996 Montero Service Manual, Volume 1, Page 52B-22 Add the new SRS troubleshooting
Page 538

Page 2180
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A2 - 87)
- 92)
Specifications
Camshaft Thrust Plate: Specifications
Mounting Bolts .....................................................................................................................................

................................................. 13 Nm (9 ft. lbs.)
Page 2678
Components

Procedure
DVD-ROM drive.
Page 5291
Page 2728
Page 6148
Note: Listed are symbols used on the table.
A slash (/) in the Material Symbol column indicates that two different materials make up a
co-polymer, while a plus (+) in this column indicates blended materials.
# Indicates there may be a difference in heat resistance temperature depending on the ratio
between the mixed materials.
* Indicates this material cannot be measured because they are made of foam as well as double
laminated materials.
Page 3915
ASSEMBLY
Locations

Lock-Up Solenoid
INSPECTION
and the ground.
Page 3739
Page 3415
Place the information on page 13A-152 of the 1997 Montero service manual:
Page 5326
Specifications
Timing Belt Tensioner: Specifications
DIMENSIONS
Movement Of Rod [1] (Or Less)

........................................................................................................................................................ 1
mm (0.0393 inch) Rod Projection Length
............................................................................................................................................. 11.7 -
12.3 mm (0.461 - 0.484 inch)
Auto Tensioner Bolt .............................................................................................................................

............................................... 24 Nm (17 ft. lbs.) Idler Pulley Bolt ......................................................
............................................................................................................................ 44 Nm (33 ft. lbs.)
Tensioner Pulley (Center) Mounting Bolt
........................................................................................................................................... 48 Nm (36
ft. lbs.) Tensioner Arm Bolt ..................................................................................................................
........................................................... 44 Nm (33 ft. lbs.)
[1] With a force of 98 - 196 N (22 - 44 lbs.) applied.

Exhaust Manifold: Testing and Inspection
Check for damage or cracking of any part.
Page 2455
Grounding Markings

Page 2950
Component View
Page 4120
1. Remove the valve vibrating stopper.
2. Remove the bolt and washer and then the throttle valve cam, pin and spring.
3. While pushing the downshift plug with a finger, use a magnet to remove the pin.
Page 2806
harness. (A3 - B1)
(A1 - Ground)
harness. (A2 - 89)
Page 4467
PARTS INFORMATION
Page 4050
Transmission Cooler: Specifications
Oil Cooler Performance .......................................................................................................................
......................................... 6,200 kJ/h (5,873 BTU/h)
Page 3762
transfer case.
transfer case.

transfer case.

Page 2494

Page 1908
main menu.
reprogramming.
Page 2432
Standard value:
INSPECTION
Page 794
on actual vehicles.
Wire Color Codes
Intake Manifold Torque and Sequence
Intake Manifold: Specifications
Torque and Sequence: Right Bank 7 Nm
Left Bank 20-23 Nm
Right Bank 20-23 Nm
Left Bank 20-23 Nm
Right Bank 20-23 Nm

Page 2695

Page 4907
Brake Master Cylinder: Service and Repair Disassembly and Assembly
1. Remove the reservoir cap and diaphragm. 2. Remove the filter, fluid level sensor and float. 3.
Remove the reservoir stopper bolt, tank and seal.
4. Remove the piston stopper bolt, gasket and stopper ring.
NOTE: Remove the piston stopper bolt and ring while depressing the piston.
Page 1647
Page 4119
Valve Body: Service and Repair Upper Valve Body
Disassembly
Page 376
Page 3296
Grounding Markings

Page 2808
increased.

Locations

Page 1874
Water Pump: Description and Operation
Water Pump Type ................................................................................................................................
......................................... Centrifugal Type Impeller
Page 7003
Map Light: Description and Operation
- Battery positive voltage is constantly applied to the reading light.
- When the reading light switch is set to the ON or OFF position, the reading light illuminates or
switches off.
Page 6005
Installation
Refrigerant Leak Repair
Refrigerant: Service and Repair Refrigerant Leak Repair
Lost Charge
If the system has lost all charge due to a leak: 1. Evacuate the system. (Refer to the evacuation
procedure.) 2. Charge the system with approximately one pound of refrigerant. 3. Check for leaks.
4. Discharge the system. 5. Repair the leaks. 6. Replace the receiver drier.
CAUTION: Replacement filter-drier units must be sealed while in storage. The drier used in these
units will saturate water quickly upon exposure to the atmosphere. When installing a drier, have all
tools and supplies ready for quick reassembly to avoid keeping the system open any longer than
necessary.
7. Evacuate and charge the system.
Low Charge
If the system has not lost all of its refrigerant charge, locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak (because of an especially low charge), add
refrigerant. If it is possible to repair the leak without discharging the refrigerant system, use the
procedure for correcting the low refrigerant level.

Resistance/Torque

Specifications
Lock Up Solenoid ................................................................................................................................

............................................................................................................. 10 Nm (86.4 inch lbs.) Shift
Solenoid No. 2 .....................................................................................................................................
............................ 10 Nm (86.4 inch lbs.)
Fuel/Emissions - Sulfur Odor From Exhaust
Fuel: Customer Interest Fuel/Emissions - Sulfur Odor From Exhaust
SUBJECT: SULFUR ODOR FROM EXHAUST
PURPOSE
Some customers may complain of a sulfur-like ("rotten egg") odor coming from the exhaust system.
Sulfur is a natural by-product of the gasoline refining process, and the amount of sulfur depends
upon the refinery's formulations. Sulfur content in fuel varies between gasoline brands and
locations.
AFFECTED VEHICLES All models
PROCEDURE
Exhaust sulfur odor does not necessarily indicate a vehicle concern, but is more likely to be directly
related to the fuel. If the vehicle has an excessive sulfur odor, check for any DTCs set in the PCM.
If any DTC is set, diagnose as described in the service manual.
If no vehicle problem is found, recommend the owner try a different brand of fuel. DO NOT
REPLACE ANY EMISSIONS COMPONENTS FOR SULFUR ODOR. PARTS REPLACEMENT
WILL HAVE NO EFFECT ON THE ODOR.
This complaint is NOT considered a warrantable condition. Repairs or replacements of catalytic

converters, oxygen sensors, or any other emissions components will have no effect on reducing or
eliminating the odor. Warranty claims submitted for such repairs or replacements will be charged
back.
Page 67
Page 248

Page 2045
Page 726
HARNESS INSPECTION
control module. -
- 86)
- Ground)

Page 3512
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Page 1502
Oil Cooler: Service and Repair
REPLACEMENT
1. Remove the radiator grille. 2. Refer to the illustration for the service procedure, noting the
following:
- When removing the eye bolts, be sure to hold the weld nut of the oil cooler while loosening the
eye bolt.
- Reverse procedure to install, ensuring the proper amount of oil is replenished.

Page 5932
scan tool.
NOTE -
Page 3085
Canister Purge Solenoid: Testing and Inspection Diagnosis Inspection
Federal
INSPECTION
Using Scan Tool
HARNESS INSPECTION
STEP 1. Check for continuity between the evaporative emission purge solenoid and the MFI relay.
-
NOTE: -
Touch the ohmmeter probes to both ends of the harness. OK: GO TO STEP 2 NG: Repair the
harness. (A1 - B1)
STEP 2. Check for an open circuit or a short-circuit to ground between the evaporative emission
purge solenoid and the engine control module. -
California
INSPECTION
Using Scan Tool

Adjustments
Shift Cable: Adjustments
NOTE: It is possible to confirm whether control cable is properly adjusted by checking whether the
park/neutral position switch is performing well.
1. Apply the parking and service brakes fully. 2. Set the selector lever to the R position. 3. Turn the
ignition key to the START position. 4. Slowly move the selector lever upward until it clicks as it fits
into the notch of the P position. If the starter motor operates when the lever makes a
click, P position is correct.
5. Then slowly move the selector lever to the N position by the same procedure as in the preceding
paragraph. If the starter motor operates when the
selector lever is at the N position, then the N position is correct.
6. Also check that the vehicle doesn't begin to move and the lever doesn't stop between P-R-N-D.
7. The control cable is properly adjusted if, as described above, the starter motor starts in both P
range and N range.
Page 812

Page 4019
Pattern Select Switch
ASSEMBLY
A. Sleeve installation. (12)
Move the selector lever to the N position and adjust the sleeve by turning it so that the distance A
between the sleeve and the tip of the lever is at the standard value.
Standard value (A): 18.2-18.9 mm (0.717-0.744 inch)

Page 7018
Page 2556
Page 20
RELAY VIEW
Door Lock Relay I

Page 906

control module.
Page 4480
Page 3441
Wire Color Codes
the marking color.

Page 473

Locations

Page 244
CONTROL UNIT VIEW

Page 3890
Standard value: 0.07 - 0.15 mm (0.0828 - 0.0059 inch) Limit: 0.3 rum (0.012 inch)
If the limit is exceeded, replace the driven gear or oil pump body.
Tip Clearance
1. Using a feeler gauge, measure the crescent-to-driven gear clearance.
If the limit is exceeded, replace the driven gear or oil pump body.
Side Clearance
1. Using a square and feeler gauge, measure the side clearance of the gears with respect to the
stator shaft mounting surface.
Standard value: 0.02- 0.05 mm (0.0008 - 0.0020 inch) Limit: 0.3 mm (0.012 inch)
If the limit is exceeded, replace the drive gear, driven gear or oil pump body.
ASSEMBLY

Page 214

Page 792

Page 2946
Page 5593

Page 2229

Page 226
CONTROL UNIT VIEW
Page 5736

DISASSEMBLY SERVICE POINT
Page 3012
follows.
that position.
Page 2213

Page 4190
F. Drive pinion rear bearing inner race removal. (21)
Use the special tools to pull out the drive pinion rear bearing inner race.
G. Oil seal/drive pinion front bearing inner race/drive pinion front bearing outer race/drive pinion
rear bearing outer race removal. (25, 26, 27 &
28) 1. Use a brass rod to drive out the drive pinion front bearing outer race from the gear carrier
together with the drive pinion front bearing inner
race and the oil seal.
2. Drive out the drive pinion rear bearing outer race in the same manner.
Inspection
NOTE: Wash the disassembled parts in cleaning solvent, dry them using compressed air, and then
check the following areas:
1. Check the companion flange for wear or damage. 2. Check the oil seal for wear or deterioration.
3. Check the bearings for wear or discoloration. 4. Check the differential case for cracks. 5. Check
the drive pinion and drive gear for wear or cracks. 6. Check the side gears, pinion gears and pinion
shaft for wear or damage. . 7. Check the side gear spline for wear or damage. .
Page 6093
Tape Player: Service and Repair
Removal
Installation

Page 2441


Page 4768
Hydraulic Assembly: Testing and Inspection

HU (MOTOR) CHECK
1. Jack up the vehicle and support it on axle stands. 2. Release the parking brake and feel the drag
force (drag torque) on each wheel brake. See: Disc Brake System/Brake Caliper/Testing and
Inspection
3. Connect the scan tool to the data link connector.
4. After checking that the selector lever is in neutral, start the engine.
CAUTION: At this time, check that the ABS warning light illuminates for a brief period before
turning off, if not, refer to "Inspection Chart For Trouble Symptoms." See: Testing and
Inspection/Initial Inspection and Diagnostic Overview
5. Depress the brake pedal to lock the wheels. 6. Select the item number on the scan tool actuator
test for the wheel to be inspected.
- Item 1 drives the front left wheel.
- Item 2 drives the front right wheel.
- Item 3 drives the rear wheels.
7. Use the scan tool to force-drive the actuator, and turn the wheel by hand to check the change in
braking force when the brake pedal is depressed.
The result should be as shown in the illustration.
NOTE: -
When the scan tool is used and the ABS system is selected, the ABS system will switch to scan
tool mode and the ABS warning light will illuminate.
- When the ABS function has been interrupted by the fail-safe, the scan tool actuator testing cannot
be used.
Page 2547

Page 1807
Radiator: Description and Operation
Radiator Type ......................................................................................................................................
.............................. Pressurized Corrugated Fin Type
Specifications

Page 1993
Page 1623
Camshaft Oil Seal: Service and Repair
1. Remove the timing belt.
2. Remove the camshaft sprocket using yolk end holder and pulley holding pins tool Nos.
MB990767 and MD998715, or equivalents.
3. Cut out a portion in the camshaft oil seal lip. 4. Cover the tip of a screwdriver with a cloth and
apply it to the cutout in the oil seal to pry off the oil seal.
CAUTION: Use care not to damage the camshaft and cylinder head.
5. When installing the camshaft oil seal, coat engine oil on the whole circumference of the oil seal
lip section.
Page 3724
Page 1971
(A1 - D6, B1 - D6, C1 - D6)
(D1 - 11, D2 - 23, D3 - 10, D5 - 51)
(D4 - Ground)
Page 3266
Grounding Markings

Page 1725
Page 6985
Wire Color Codes
the marking color.

Specifications
..................................................................... 1.12 W
Page 6370
NOTE:
WARNING:
NOTE:
Page 2651
(A4 - 79, B4 - 76, C4 - 73, D4 - 75)
(A3 - 42, 63 - 34, C3 - 43, D3 - 35)
D2 - 92)

Page 4114
Valve Body: Service and Repair Lower Valve Body
Disassembly
1. Remove the steel ball and the check ball. 2. Remove the check ball.
Lock-Up Solenoid
INSPECTION
and the ground.
Page 675
Torque 1.5 ft.lb

Page 2233
on actual vehicles.
Wire Color Codes
Page 4115
3. Remove each bolt and then remove the shift solenoids No. 1, No. 2 and lock up solenoid. 4.
Remove the O-ring from each solenoid.
6. Remove the plug, spring and 1-2 shift valve.
7. Examine which groove of the primary regulator valve sleeve engages with the seat.
CAUTION: Because this has influence on the line pressure, make a note of it.
8. While pushing the sleeve with a finger, use a magnet to remove the seat.
Page 6478
Brake Warning Indicator: Electrical Diagrams

Page 5965


Page 5027
Starter Relay
Page 3580
Page 7020
Marker Lamp: Testing and Inspection
and Inspection
- Check the bulb.

Page 6273
Heated Element: Electrical Diagrams

Back Door Window Defogger And Mirror Heater (Part 1 Of 2)
Page 605
Page 636
HARNESS INSPECTION
NOTE: -

Page 186
Measurement method
parts.
power transistor.

Locations

Specifications
Brake Caliper: Specifications
Cylinder Inner Diameter 1.69 in
Assembly Bolt 65 ft.lb
Brake Hose Flare Nut 11 ft.lb
Bleed Screw 6 ft.lb
Guide Pin 54 ft.lb
Lock Pin 54 ft.lb

Page 1593
on actual vehicles.
Wire Color Codes
Direct Clutch
Page 851
Page 1339
Hazard Light Switch

Page 1420
NOTE ^
system.

Page 161
RELAY VIEW

Page 2722

Page 6922

Page 3391


Page 5871
1996 Galant Service Manual, Volume 1, Page 52B-27 Add the new SRS troubleshooting
Page 5477
Steering Gear: Mechanical Specifications
Ratio ....................................................................................................................................................
................................................................. 16.4 - 18.0
Backlash Limit .....................................................................................................................................

.................................................. 0.5 mm (.020 inch)
Jam Nut ...............................................................................................................................................

............................... 147-176 Nm (108-123 ft. lbs.) Lower Joint Assembly Connecting Bolt
..................................................................................................................................... 29-34 Nm
(22-25 ft. lbs.) Power Steering Hoses ..................................................................................................
......................................................................... 15 Nm (11 ft. lbs.) Steering Gear Mounting Nut
.......................................................................................................................................................
54-64 Nm (40-47 ft.lbs.) Steering Gear Side Cover Bolts
.............................................................................................................................................................
49 Nm (36 ft.lbs.) Valve Housing Bolts ................................................................................................
.............................................................................. 49 Nm (36 ft.lbs.)
Specifications
Bracket Bolt .........................................................................................................................................

............................................................................................................................... 5 Nm ( 3.6 ft. lbs.)
Ignition Coil: Component Tests and General Diagnostics
Ignition Coil
Ignition Coil
Primary Coil Resistance
1. Measure the resistance between the terminals for each ignition coil.
Standard value: 0.74 - 0.90 Ohms
Ignition Coil
Secondary Coil Resistance
2. Measure the resistance between the high-tension terminals for each ignition coil.
Measurement points No.3 - No.6 cylinder side coil
A coil
No.1 - No.4 cylinder side coil B coil
No.2 - No.5 cylinder side coil C coil
Standard value: 20.1 - 27.3 K Ohms
Inspection

Page 516
Page 4698

Page 4079
Locations
Page 3954
Page 4112
3. Install the two solenoid oil strainers and one throttle oil strainer to the lower valve body.
4. Install the two springs and then the check valve and pressure relief valve to the lower valve
body.
Spring
Valve
5. In alignment with the bolt holes, install a new valve body gasket No. 1 on the upper valve body.
6. In alignment with the bolt holes, put the plate on the gasket No. 1.
Page 2049

Page 1025
8. Using a crankshaft spacer tool No. MD998769, or equivalent, rotate the crankshaft a quarter of a
turn counterclockwise. Then rotate it
back clockwise to verify that all the timing marks are in alignment.
9. Install a torque wrench and tension pulley wrench tool No. MD998767, or equivalents, on the
tensioner pulley.
10. Torque it to 4.4 Nm (3.3 ft. lbs.) with the torque wrench. 11. While holding the tensioner pulley
in position, tighten the center bolt to 48 Nm (36 ft. lbs.). 12. Rotate the crankshaft two turns
clockwise and let it stand for approximately 5 minutes.
13. Check to see whether the metal wire inserted when the auto tensioner was installed can be
removed without any resistance.
NOTE: If the metal wire can be removed without any resistance, it means that the belt is correctly
tensioned. Therefore, remove the metal wire. In this condition, check that the projection of the rod
of the auto tensioner is within the standard value of 3.8 - 5.0 mm (0.150 - 0.196 inch).
14. If the metal wire cannot be removed easily, repeat steps, 9 through 12, until correct belt tension
is obtained.
Corrections
DTCs.
NOTE:

Meter
Meter
Disassembly Steps
Disassembly
Reassembly

Page 308
SENSOR VIEW

Page 2691

Page 1183

Page 6969

Page 6749
Page 3451
Torque 1.5 ft.lb

Page 4462
Page 6288
BODY COLORING
Page 5994
Page 5404
Part 1 Of 3
Page 3718

Page 5860
Air Bag: Technical Service Bulletins SRS Air Bag Troubleshooting - Revision
NO.: TSB-97-52B-002 Date: February, 1997 MODEL: See Below
Subject: ADDITIONAL SRS AIR BAG TROUBLESHOOTING PROCEDURES - SERVICE

MANUAL REVISION
[TSB Revision TSB-97-52B-002]
PURPOSE This bulletin updates information in the affected service manuals and also contains new
additional SRS air bag troubleshooting and inspection procedures.
AFFECTED VEHICLES 1992-96 Expo/Expo LRV 1992-97 3000GT 1993-97 Mirage 1992-96
Diamante 1992-97 Montero 1994-97 Galant 1995-97 Eclipse
AFFECTED MANUALS 1992-96 Expo/Expo LRV Service Manual, Volume 1, Page 52B-23
1992-96 3000GT Service Manual, Volume 1, Page 52B-25 1997 3000GT Service Manual, Volume
1, Page 52B-16 1993-96 Mirage Service Manual, Volume 1, Page 52B-3O 1997 Mirage Service
Manual, Volume 1, Page 52B-15 1992-96 Diamante Service Manual, Volume 1, Page 52B-31
1992-95 Montero Service Manual, Volume, 1, Page 52B-22 1996 Montero Service Manual, Volume
1, Page 52B-22 1997 Montero Service Manual, Volume 1, Page 52B-14 1994-95 Galant Service
Manual, Volume 1, Page 52B-23 1996 Galant Service Manual, Volume 1, Page 52B-27 1997
Galant Service Manual, Volume 1, Page 52B-17 1995 Eclipse Service Manual, Volume 1, Page
52B-24 1996 Eclipse Service Manual. Volume 1, Page 52B-17 1997 Eclipse Service Manual,
Volume 1, Page 52B-17

Page 6700

4.
Page 3528


Page 7033
Page 7125
Vanity Mirror Light
Page 423

Page 868

Page 3423
Install the gasket with the projection in the position shown in the illustration.
CAUTION: If the gasket installation direction is incorrect, it may result in faulty idling or other
trouble.
Page 4182
Differential Carrier: Service and Repair Rear Axle
Replacement
REMOVAL
1. Drain differential gear oil. 2. Follow removal steps outlined in illustration.

Page 606
OPERATION
Specifications
EGR Control Solenoid: Specifications Solenoid Resistance
Solenoid Resistance

Page 1480
Page 5419
1984-97 Montero
Page 556
INSPECTION
disconnected
connector parts.
sensor connector.
position sensor.

Page 2426


Page 5351
OPERATION
high to low.
Page 2835

Bleeding System
Power Steering Fluid: Service and Repair Bleeding System
Check the stationary steering effort. If it is different from the standard value, there is probably air in
the system, so bleed the system.
NOTE: After removing and installing the oil pump, loosen the drive belt and turn the pump pulley by
hand several times to supply steering fluid to the pump.
1. Disconnect the ignition power transistor connector (6 pin). 2. Jack up the front wheels and
support them by using a rigid rack. 3. Turn the steering wheel all the way to the left and to the right
five or six times. 4. While operating the starting motor intermittently, turn the steering wheel all the
way to the left and right five or six times (for 15 to 20 seconds).
CAUTION: -
During air bleeding, refill the steering fluid supply so that the level never falls below the lower
position of the filter.
- If air bleeding is done while engine running, the air will be broken up and absorbed into the fluid;
be sure to do the bleeding only while cranking.
5. Confirm that the steering fluid level is between the high and low marks on the dipstick. 6.
Reconnect the ignition power transistor connector 7. Start the engine and allow it to run at idle. 8.
Turn the steering wheel to the left and right. Repeat until there are no air bubbles in the oil reservoir
fluid. 9. Confirm that the fluid is not milky, and that the level is up to the specified position on the
dipstick.
10. Confirm that there is very little change in the fluid level when the steering wheel is turned to the
left and right.
11. Confirm whether or not the change in the fluid level is within 5 mm (.20 inch) when the engine is
stopped and when it is running. 12. If necessary, repeat the bleeding procedure until the fluid is not
milky (no bubbles) and the power steering pump makes no noise while engine is
running at idle.
CAUTION: -
If the change of the fluid level is 5 mm (.20 inch) or more, the air has not been completely bled from
the system, and thus must be bled completely.
- If the fluid level rises suddenly after the engine is stopped, the air has not been completely bled.
- If air bleeding is not complete, there will be abnormal noises from the pump and the flow-control
valve, and this condition could cause a lessening of the life of the pump, etc.
Page 3888
Page 4511
Locations

Page 2990
OPERATION
control motor.
California
HARNESS INSPECTION

Locations
Fuse: Locations
Name Symbol
Fusible Links 1-7 A
Page 1771
Wire Color Codes
the marking color.

Page 1248
Specifications
Fluid Pick-Up: Specifications
Oil Strainer ...........................................................................................................................................

.................................... 10 Nm (86.4 inch lbs.) Oil Screen ...................................................................
................................................................................................................... 7 Nm (60 inch lbs.)
Specifications
Firing Order .........................................................................................................................................

............................................................. 1-2-3-4-5-6.
Page 3675

Service and Repair
Keyless Entry Transmitter Battery: Service and Repair
1. Remove the set screw to remove the battery from the transmitter. 2. Install a battery with its (+)
side face-down.
Note: Battery required for replacement: Coin type battery CR2032
3. Insert the claw first, and with care not to displace the 0-ring, assemble the transmitter.
Note: Do not let water or dust stick to the inside of the transmitter when its open. Also, do not touch
the precision electronic device. If the 0-ring is displaced during the assembly of the transmitter,
water or dust penetrates it, causing trouble.
Precaution
PURPOSE
AFFECTED VEHICLES

Page 2153

Specifications
Low Fuel Lamp/Indicator: Specifications
Low fuel warning light ..........................................................................................................................
.................................................................. 3.4 (158)
NOTE: The values in parentheses denote SAE trade numbers.

Alternator
Drive Belt: Specifications Alternator
When checked
A: .........................................................................................................................................................
...................... 5.0 - 7.0 mm (0.20 - 0.28 inch) B: .................................................................................
............................................................................................... 7.5 - 9.5 mm (0.30 - 0.37 inch)
When new belt is installed
A: .........................................................................................................................................................
...................... 4.0 - 5.0 mm (0.16 - 0.20 inch) B: .................................................................................
............................................................................................... 5.5 - 7.5 mm (0.22 - 0.30 inch)
When used belt is installed
A: .........................................................................................................................................................
...................... 5.5 - 6.5 mm (0.22 - 0.26 inch) B: .................................................................................
............................................................................................... 8.0 - 9.0 mm (0.31 - 0.35 inch)
TENSION
When checked .....................................................................................................................................

.................................................................................................................................................... 637 -
................................................................................................................................................... 441 -
539 N (98 - 119 lbs.)
Fasteners
M8 ........................................................................................................................................................
......................................... 21 Nm (15 ft. lbs.) M10 ..............................................................................
................................................................................................................. 51 Nm (38 ft. lbs.)
Recall 00V311000: Possible Loss of Power Steering
Harmonic Balancer - Crankshaft Pulley: All Technical Service Bulletins Recall 00V311000: Possible
Loss of Power Steering
Mirage model vehicles equipped with 1.5L engines; Montero Sport models equipped with 3.0L
engines; and Montero models equipped with 3.0L engines. The bolt securing the crankshaft pulley
can become loose and the pulley could fall off the vehicle.
The condition can result in a loss of power steering assist, increasing the risk of a crash.
On the Mirage vehicles, the dealers will install a new, improved crankshaft pulley bolt on the older
engines. On new engines which already have the improved bolt, the dealer will tighten the
crankshaft pulley bolt to the correct torque specification. On the Montero models, dealers will
tighten the crankshaft pulley bolt to the correct torque specifications. If the bolt is damaged, it will
be replaced.
Owner notification will be performed in five separate owner mailings, with the first mailing beginning
October 31, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon
service date and do not receive the free remedy within a reasonable time should contact Mitsubishi
at 1-800-222-0037. Also contact the National Highway Traffic Safety Administration's Auto Safety
Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Page 5090
Page 4314
ASSEMBLY
Bleeding System
Power Steering Fluid: Service and Repair Bleeding System
Check the stationary steering effort. If it is different from the standard value, there is probably air in
the system, so bleed the system.
NOTE: After removing and installing the oil pump, loosen the drive belt and turn the pump pulley by
hand several times to supply steering fluid to the pump.
1. Disconnect the ignition power transistor connector (6 pin). 2. Jack up the front wheels and
support them by using a rigid rack. 3. Turn the steering wheel all the way to the left and to the right
five or six times. 4. While operating the starting motor intermittently, turn the steering wheel all the
way to the left and right five or six times (for 15 to 20 seconds).
CAUTION: -
During air bleeding, refill the steering fluid supply so that the level never falls below the lower
position of the filter.
- If air bleeding is done while engine running, the air will be broken up and absorbed into the fluid;
be sure to do the bleeding only while cranking.
5. Confirm that the steering fluid level is between the high and low marks on the dipstick. 6.
Reconnect the ignition power transistor connector 7. Start the engine and allow it to run at idle. 8.
Turn the steering wheel to the left and right. Repeat until there are no air bubbles in the oil reservoir
fluid. 9. Confirm that the fluid is not milky, and that the level is up to the specified position on the
dipstick.
10. Confirm that there is very little change in the fluid level when the steering wheel is turned to the
left and right.
11. Confirm whether or not the change in the fluid level is within 5 mm (.20 inch) when the engine is
stopped and when it is running. 12. If necessary, repeat the bleeding procedure until the fluid is not
milky (no bubbles) and the power steering pump makes no noise while engine is
running at idle.
CAUTION: -
If the change of the fluid level is 5 mm (.20 inch) or more, the air has not been completely bled from
the system, and thus must be bled completely.
- If the fluid level rises suddenly after the engine is stopped, the air has not been completely bled.
- If air bleeding is not complete, there will be abnormal noises from the pump and the flow-control
valve, and this condition could cause a lessening of the life of the pump, etc.
Page 5897
CONTROL UNIT VIEW
Page 4168
3. Check the tooth contact of the drive gear and drive pinion.
NOTE: Checking the tooth contact pattern is the way to confirm that the adjustments of the pinion
height and backlash have been done properly. Continue to adjust the pinion height and backlash
until the tooth contact pattern resembles the standard pattern. If the correct tooth contact pattern
cannot be obtained even after adjustments, the drive gear and the drive pinion must be worn
beyond the allowable limit. Replace the gear set.
Disassembly
Fluid Pan: Mechanical Specifications
Oil Pan .................................................................................................................................................

...................................... 8 Nm (69.6 inch lbs.)
Locations

Locations

Page 1613


Locations

Page 4092
INSPECTION
Page 6497
Cigarette Lighter: Description and Operation
- When the plug is inserted into the socket, the cigarette lighter turns on.
- Within 18 seconds after the plug element has started heating, the plug will automatically return
and the cigarette lighter will switch off.
- Current flows via dedicated fuse No. 5, and the cigarette lighter illumination light and ashtray
illumination light illuminate.
Page 5101
Starter Armature: Testing and Inspection Commutator Inspection
Commutator
1. Place the armature on a pair of V-blocks, and check the deflection by using a dial gauge.
Standard value: 0.05 mm (0.0020 in.) Limit: (0.0040 in.)
Commutator
2. Check the outer diameter of the commutator.
Standard value: 29.4 mm (1.158 in.) Limit: 28.4 mm (1.118 in.)
Commutator
3. Check the depth of the undercut between segments.
Standard value: 0.5 mm (0.020 in.)

Page 7170
1. Place the drum, guide, regulator, etc. on the work bench as shown.
a. Place the drum so the square hole side faces upward.
b. Place the guide with the slits up.
c. Place the regulator with the glass bracket down, and leave the glass in its fully open position.
Note:
Use only one spring (A or B) depending on the model being repaired.
2. Put the wires through the springs. Install the lowering wire to the guide first, then install the lifting
wire. (The lifting wire should be placed over the lowering wire.)
3. Using a wire (about 0.5 mm in diameter) and twisting, compress the spring.
Note:
Bind the wires at a slit portion of the guide.

Page 2230
Grounding Markings

Page 5294
Page 2654
(A4 - 76, B4 - 79)
(A3 - 34, B3 - 42)
- 92)

Page 1113
6. If the refrigerant's pressure is higher than the limit shown for a given temperature, slowly vent
the vapor from the top of the container into the recovery/recycling unit. Continue until the pressure
falls below the limit shown in the R12 or R134a chart. If the refrigerant is R134a and the pressure
still exceeds the limits shown in the chart, shake the container and let it stand for several minutes.
If the pressure then falls below the limits, it is OK to use as is. Should the pressure inside the
container still exceed the pressure limit shown, recycle the entire contents.
System Flushing
Now that CFCs cannot legally be vented to the atmosphere, flushing compounds such as R11 and
R113 are no longer viable for flushing systems. To flush oil out of an R12 system when retrofitting
for RI34a, you can use a recycling machine and liquid R12, which picks up the mineral oil used with
R12 and takes it out. Do not use flammable solvents like mineral spirits or lacquer thinners. They
are fire and explosion hazards.
Typical Cause of A/C System Contamination
Following are the most probable causes of contamination in automotive A/C systems:
^ Mixing refrigerants
^ Contaminated service equipment
Mixing Refrigerants
Under no circumstances should a system be charged with any refrigerant other than the refrigerant
specified on the labels on the vehicle. To do so contaminates the system and can cause damage to
the system and the equipment. Damage may include compressor failure, damage to recycling
equipment, and transfer of contaminated refrigerant to other vehicles. If R12 and R134a are mixed,
the mixture cannot be readily identified. Also, increases in system pressure of as much as 25% can
occur, resulting in performance degradation and possible system damage.
Contaminated Service Equipment
Service equipment must be used with only one refrigerant. Recycling equipment, hoses, gauges,
and manifolds used for R134a systems cannot be used for servicing R12 systems. A shop that
services both R134a systems and R12 systems must have duplicate sets of equipment. The
practice of flushing a system with CFCs can no longer be continued because federal and local laws
prohibit venting of CFCs into the atmosphere.
Disposing of Contaminated Refrigerant

Removal and Installation
Brake Master Cylinder: Service and Repair Removal and Installation

CAUTION: Do not remove the check valve from the vacuum hose. If the check valve is defective,
replace it together with the vacuum hose.
1. Drain the brake fluid. 2. Remove the fluid level connector and sensor. 3. Remove the brake tube
connection. 4. Remove the master cylinder assembly. 5. Replenish the reservoir with new brake
fluid. Bleed the master cylinder and the hydraulic system. See: Master Cylinder Bleeding 6. Adjust
the brake pedal. See: Brake Pedal Assy/Adjustments
Page 2416
connected.)
connector.
increased.
Page 7064
Grounding Markings

Page 5631
DISASSEMBLY
disc, if necessary.
BEARING REPLACEMENT
Page 6698

Page 193

Page 3245
HARNESS INSPECTION
STEP 1. Check for continuity between the injectors and the MFI relay. Injector intermediate
harness connector: Disconnected -
NOTE: -
STEP 2. Check for an open circuit or a short-circuit to ground between the injector and the engine
control module. -
- Injector intermediate harness connector: Disconnected OK: STOP

Page 761
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A2 - 87)
- 92)
Page 6458
Grounding Markings

Page 3978
Page 412
Point F:.................................................................................................................................................
..................................................3 ± 2 Ohms Point E:...........................................................................
...................................................................................................................110 ± 7 Ohms
touching stopper.
Standard value:
A:..........................................................................................................................................................
..........................................119.3 mm (4.69 in.) B:................................................................................
..................................................................................................................255.0 mm (10.03 in.)
Page 2173

Locations

Page 6607


Service and Repair
Antenna Cable: Service and Repair
Whip Antenna And Antenna Feeder Cable - Removal And Installation
Removal
To remove follow the steps listed in the image and note the following:
Antenna Base And Feeder Cable Removal
Step 8: Antenna Base and Feeder Cable Removal For ease of installation, tie a cord which is
approximately 3 m (9.84 ft.) in length to the feeder cable. Pull out the feeder cable together with the
antenna base.
Installation

Lock-Up Solenoid
INSPECTION
and the ground.
Page 4681
Component View
Page 3672
CONTROL UNIT VIEW
Page 5041
Battery: Description and Operation Charge Rate
If the test indicator is white, the battery should be charged as outlined below. When the dot
appears or when maximum charge shown below is reached, charging should be stopped.
NOTE: When the charging is performed at 5 amps, charging is virtually 100% three hours after the
indicator's indication changes from white to green. Use fast charging only in an emergency. If the
indicator does not turn to green even after the battery is charged, the battery should be replaced;
do not overcharge.
Charge Rate Chart
Charge Rate Chart

Page 3429
Throttle Cable/Linkage: Component Tests and General Diagnostics
Cable Check and Adjustment
1. Make sure that the throttle lever and the bracket have no transformations. 2. Remove the boot at
the outer cable so that the inner cable stopper can be seen. 3. Measure the dimension between the
end of the inner cable stopper and that of the outer cable with throttle lever full open.
Standard value: 34-35 mm (1.34-1.38 inch)
4. If the distance is outside the standard value, adjust using the adjusting nut.
Cable Stopper Adjustment
1. When replacing the old throttle cable with a new one, the throttle cable stopper will not be
secured, and so you will need to secure it by the
following procedure: a. Install the new throttle cable to the automatic transmission assembly so that
it is routed correctly, and then secure it. (However, it should not be
connected to the throttle body yet.)
b. Remove the dust cover from the outer cable. c. Gently pull the inner cable with a force of
approximately 2 N (0.44 lbs.) to remove any slack from the cable. d. While pulling the cable, move
the stopper until it is at the position shown in the illustration, and then crimp it to secure it in that
position. e. Place the dust cover back over the outer cable. f.
Connect the inner cable to the throttle body, and the carry out throttle cable adjustment.
Page 6142

procedures apply.
Page 6613
Low Fuel Lamp/Indicator: Testing and Inspection
The low fuel warning light does not illuminate even if fuel in the fuel tank is less than 11 cubic
decimeter (2.9 gals). -
Check the warning light bulb.
- Check the fuel level sensor.

Locations

Page 4457
Page 2593


Page 2325
on actual vehicles.
Wire Color Codes
Page 5930

Page 2601
Checking the operation
(1) Remove the throttle body. (2) Remove the stepper motor.
(3) Connect the special tool (test harness) to the idle air control motor connector. (4) Connect the
positive terminal of a power source (approx 6 V) to the white clip or the green clip.
(5) While holding the idle air control motor as shown in the illustration, connect the negative power
source terminal to each clip in the sequence
described below, and check whether or not there is vibration (a feeling of very slight shaking of the
stepper motor) as a result of activation of the stepper motor. 1) Connect the negative power source
terminal to the red and black clips. 2) Connect the negative power source terminal to the blue and
black clips. 3) Connect the negative power source terminal to the blue and yellow clips. 4) Connect
the negative power source terminal to the red and yellow clips. 5) Connect the negative power
source terminal to the red and black clips. 6) Repeat the test in the reverse (5-1) sequence.
(6) If vibration is felt as a result of this test, the stepper motor can be considered to be normal.
Page 2550


Page 6905

Specifications
Flex Plate: Specifications
Mounting Bolts .....................................................................................................................................

................................ 72 - 76 Nm (53 - 56 ft. lbs.)
Page 2495
Grounding Markings

Page 2214
Grounding Markings

Torque 1.5 ft.lb

Page 4333
AFFECTED VEHICLES
1995-99 Montero
PROCEDURE

Page 6920
on actual vehicles.
Wire Color Codes
Locations
Hazard Warning Flasher: Locations

Page 740
Page 4783
NOTE: -
Fluid - M/T: Capacity Specifications
Specification ........................................................................................................................................
........................................................................ 3.3 qts.
Page 1847
Sensor .................................................................................................................................................
........................................ 10 - 12 Nm (7 - 9 ft. lbs.)
HARNESS INSPECTION
Page 2095

Page 484
- Example 2
normal.
Page 2415
Page 1553

Page 3680
Wire Color Codes
the marking color.

Page 699
Component View
Page 5290
Page 4908
5. Remove the primary and secondary piston assembly 6. Reverse procedure to assemble. Ensure
that the hydraulic system is bled. See: Master Cylinder Bleeding
Page 3714

Service and Repair

Page 4327
NOTE:
Page 288
SENSOR VIEW
G Sensor O
Page 1174
Centralized Relay
Page 524

Resistance/Torque
Design Thermistor

Page 2642


Page 4642
Grounding Markings

Page 833
SENSOR VIEW

Page 2251
Page 2533
MAIN MENU
IMPORTANT
connectors.

the main menu.
Locations

Torque 1.5 ft.lb

Power Steering Fluid: Capacity Specifications
Specification 1.12 qt (US)

Page 3700

Specifications
Inclinometer: Specifications
Inclinometer is a Gravity type Meter. Inclinometer Damping System is an Oil-filled damping system
Page 2698


Page 2549

Page 7017
Marker Lamp: Electrical Diagrams

Page 2557
Page 5621
BEARING REPLACEMENT
Page 5850
1997 Eclipse/Eclipse Spyder, Volume 1, page 52B-4
Page 5394
f. Lock nut installation (13). Use the special tool to tighten carefully until the lock nut contacts the
bearing race.
g. Main shaft end play adjustment (-).
1. Adjust the play by tightening the lock nut gradually so that the mainshaft end play will meet the
range of standard value.
Standard value: 0.03 mm (.0012 inch) or less
2. Use a punch to crimp the circumference of the lock nut in order to secure the lock nut. 3. Check
that the mainshaft rotates smoothly.
h. Rack piston installation (16).
1. Install the rack piston until it comes in contact with the edge of the main shaft. 2. Rotate the main
shaft to align the ball raceway with the 19-ball insertion hole.
Page 615
SENSOR VIEW

Page 1853

Page 2390
Spark Plugs

Limit : 1.3 mm (0.051 in.)
a plug cleaner and
Spark Plug Cable

Page 4215
2. Set case B downward and remove case A, side gear spacer (RH) and side gear (RH).
NOTE: Check differential gear backlash to determine necessity of disassembling side (RH) and
onward.
B. Differential gear backlash check. (-)
Check differential gear backlash as follows: 1. Insert cloth wrapped screwdriver through side of
case B and lock side gear (LH) and pinion gear. (one piece). 2. Contact dial gauge on pinion gear
facing the locked pinion gear and measure backlash within the standard value.
NOTE: Measure 2 pinion gears.
Standard value:
Conventional differential: 0.10-0.25 mm (0.004-0.01 inch) Rear differential lock: 0.15-0.20 mm

(0.005-0.008 inch)
3. When backlash exceeds the standard value, adjust side gear spacer (LH).
NOTE: If backlash is within the standard value, assure appropriate gear spacer (RH) thickness and
assemble differential case assembly.
INSPECTION
NOTE: Wash the disassembled parts in cleaning solvent, dry them using compressed air, and then
check the following areas:
1. Check the side gears, pinion gears and pinion shaft for wear or damage. 2. Check the side gear
spline for wear or damage.
ASSEMBLY
A. Backlash adjustment on differential gear case B side. (-)
Adjust backlash on differential gear case B side as follows:
1. Temporarily install side gear spacer (LH), side gear (LH), washers, 2 pinion gears and pinion
shaft A on case B.
NOTE: Do not assemble pinion shaft holder, pinion shaft-B or the remaining pinion gears (2).
2. Insert wrapped screwdriver through side of case B to lock one side of pinion gear and side gear
(LH.).
Locations

Page 4470
INSPECTION
Page 3934
Planetary Gears: Service and Repair Rear Planetary Gear, Output Shaft and First & Reverse Brake
DISASSEMBLY

Page 3422
Throttle Body: Service and Repair Removal and Installation
PAGE REFERENCE
>A< GASKET INSTALLATION

Front Combination Light
Turn Signal Lamp: Specifications Front Combination Light
Front turn-signal light ...........................................................................................................................
.......................................................... 27/8 (1157) W

Page 512
Page 3098

Page 3630
GAP

Locations

Page 2135

Page 757
Wire Color Codes
the marking color.

Page 2102
OPERATION
Page 4919
Parking Brake Lever: Service and Repair
REPLACEMENT
1. Remove the floor console assembly. 2. Remove the parking brake cable connection. 3. Remove
the baking brake stay and bushing. 4. Remove the parking brake shaft cover. 5. Remove the
parking brake switch connector, switch and then the lever. 6. Reverse procedure to install, ensuring
proper stroke adjustment of the brake lever. See: Adjustments
Page 2775

Resistance/Torque
Design Thermistor

Page 2854
on actual vehicles.
Wire Color Codes
Page 745
Page 6536
Page 2481

NOTE: -
(A1 - Ground)
(A2 - 88)
Locations

Page 2301

Page 235

Locations
COMPONENT VIEW VIEW

Page 2163
Page 4296
Constant Velocity Joint Boot: Fluid Type Specifications
SPECIFIED LUBRICANT
Double-Offset Joint (D.O.J.) and Birfield Joint (B.J.) Assemblies: Repair Kit Grease.
Page 4198
4. Use the special tool to turn both right and left side bearing nuts one half the distance between
the centers of two neighboring holes to apply
the preload.
5. Measure the drive gear runout.
Limit: 0.05 mm (0.0020 inch)
6. If the drive gear runout exceeds the limit, remove the -differential case and the drive gears, move
them to different positions and then
reinstall them.
7. Choose and install the lock plates (two types). 8. Check the final drive gear tooth contact. If poor
contact is evident, carry out adjustment.
Page 5975

Page 5766
Refrigerant: Fluid Type Specifications TYPE
TYPE
R-134a (HFC-134a)
Page 2522
Removal
Installation
Dome Lamp: Diagram Information and Instructions
Page 1634
seal.
CAUTION: Use care not to damage the crankshaft and oil seal case.
6. Using the tool, press fit a new crankshaft rear oil seal into the oil seal case. 7. Use the flywheel
stopper tool to secure the flywheel assembly, and tighten the bolts to 72 - 76 Nm (53 - 56 ft. lbs.).
Page 3084
4. Apply a vacuum and check for air-tightness when voltage applied directly to the evaporative
emission purge solenoid and when the voltage is
discontinued.

Specifications
Torque 7 ft.lb
Page 1161
Grounding Markings

Page 2142
OPERATION
Rear 1300-1500 ohms

Page 1825

Resistance/Torque
Design Thermistor

INSPECTION
Page 6981
Grounding Markings

V4AW2 A/T.
23A-45
Lifter / Lash Adjuster: All Technical Service Bulletins Valve Lash Adjuster Noise - Troubleshooting
Procedures

PROCEDURES
Starion
shown.
PROCEDURES

checks:
NOTE: (1)
adjuster.
Replacement

REMOVAL

Fuel Injector: Diagram Information and Instructions
Page 2901
on actual vehicles.
Wire Color Codes
Part 1 Of 3
Locations

Page 5259

Page 3677

Page 4014
REMOVAL
INSPECTION
Specifications
Leak Detection Solenoid: Specifications Solenoid Resistance
Solenoid Resistance

Page 5443
1998 & 1999 Montero Service Manuals, Volume 2, page 37A-39 2000 Montero Service Manual,
Volume 2, page 37A-35
Diagrams
Firewall: Diagrams
DASH PANEL
1. The previous dash panel with an upper-lower block structure has been changed to a single
structure, to provide increased corrosion resistance and
sound reduction.
2. Together with the single structure of the dash panel, the fender shield connection section is
located on the tilted surface of the dash panel, and the
structure effectively receives the input from the No.1 mounting along the shear direction.
Replacement

REMOVAL

Page 2431
increases.
INSPECTION
Using Scan Tool
HARNESS INSPECTION
- 92)
(A6 - 72)
Page 3406

Page 2270
OPERATION
control motor.
Page 6515
Wire Color Codes
the marking color.

Page 1770
on actual vehicles.
Wire Color Codes
Page 1258
2. Loosen the camshaft bearing cap bolt. Do not remove the bolts from the cap. 3. Remove the
rocker arm, shaft and bearing cap as an assembly. 4. Apply engine oil to the camshaft journals and
cams and then install the camshafts. Use care to prevent confusion of the rear and front bank
camshafts.
NOTE: The right bank camshaft is identified by a slit 4 mm wide at the rear end of the camshaft.
5. Check to see that the dowel pin of the camshaft is located at the position shown.
6. Immerse the lash adjuster in clean diesel fuel. 7. Using the lash adjuster retainer and the air
bleed wire tools Nos. MD998441 and MD998441, or equivalents, move the plunger up and down 4
or 5
times while pushing down lightly on the check ball in order to bleed out the air.
8. Insert the lash adjuster to rocker arm, being careful not to spill the diesel fuel. Then use the lash
adjuster holder tool to prevent the adjuster from
falling out while installing it.

Page 3862
DISASSEMBLY
ASSEMBLY

Page 3460
Wire Color Codes
the marking color.

Page 2680
connector.
NOTE:
Page 2889
Standard value:
oxygen sensor.
Page 2607
RELAY VIEW

Page 814
on actual vehicles.
Wire Color Codes
Page 444
on actual vehicles.
Wire Color Codes
Page 4124
VALVE SPRING
1. Check the free height and outside diameter of each spring.
Assembly
1. Install the low coast modulator valve, spring and plug as illustrated. 2. While pushing the plug
with a finger, install the seat.
3. Install the 2-3 shift valve, spring and plug as illustrated. 4. While pushing the plug with a finger,
install the key.
Page 6802
Volt Meter Gauge: Description and Operation
- When the ignition key is turned to the "ON" position, the voltage meter operates and indicates a
battery positive voltage of approximately 12 V.
- When the engine is started, the voltage meter indicates a battery positive voltage of 12 to 16 V,
indicating that the battery is on charge.
For Front Seat
Auxiliary Power Outlet: Service and Repair For Front Seat
Removal
Installation

Page 1500
Front Planetary Gear
Specifications
Lock Up Solenoid ................................................................................................................................

............................................................................................................. 10 Nm (86.4 inch lbs.) Shift
Solenoid No. 2 .....................................................................................................................................
............................ 10 Nm (86.4 inch lbs.)
Page 303
Page 2460
Page 1555

Page 6416
Accelerator Cable
(1) While holding link (C) so that it is touching the stopper, adjust the play of the accelerator cable
with the adjusting nut so that the cable play is
at the standard value.
Standard value ELC-4A/T 2 - 3 mm (0.08 - 0.12 in.) Except ELC-4A/T 0 - 1 mm (0 - 0.04 in.)
(2) After adjusting, secure the cable with the lock nut.
Auto-cruise Control Cable
(1) While holding link (A) so that it is touching link (B), adjust the play of the cruise control cable
with the adjusting nut so that the cable play is
at the standard value.
Standard value: 1 - 2 mm (0.04 - 0.08 in.)
(2) After adjusting, secure the cable with the lock nut.
Page 2618

Page 651
Wire Color Codes
the marking color.

Page 4268

Page 1452
1997 Montero Service Manual, Volume 1, Page 11B-35 Correct the exhaust valve face service limit
as shown.
Input Speed Sensor
INSPECTION
Specifications
.............................................................................................................................................. 1.12 W
Page 3823
Heated Element: Diagram Information and Instructions
Page 536
INSPECTION
Using Scan Tool
HARNESS INSPECTION
harness. (A2 - 92)
(A1 - 83)

Page 2855
Wire Color Codes
the marking color.

Page 3861
Standard value: 2.90 - 4.29 mm (0.1141 - 0.1689 inch)
ASSEMBLY
B. Cushion plate installation. (7)
1. Install the cushion plate to the forward clutch drum so that its convex side is oriented to the
piston side.
C. Clutch flange installation. (4)
1. Install the clutch flange to the forward clutch drum so that the flange's chamfer is oriented to the
disc side.
D. Snap ring installation. (3)
1. Install the snap ring so that the end gap of the snap ring is not aligned with the inner cutout of
the direct clutch drum.
Second Coast Brake Piston

Page 394


Page 667
OPERATION
control motor.
Page 2747
Page 7027
Grounding Markings

Page 6972
Wire Color Codes
the marking color.

Page 1748
Page 1396
14. When replacing the bearing, select the proper bearing according to the crankshaft identification
color and the connecting rod identification mark
and install it.
15. Liberally coat the circumference of the piston, piston ring, and oil ring with engine oil.
16. Arrange the piston ring and oil ring gaps (side rail and spacer) as shown in the illustration. 17.
Rotate the crankshaft so that the crank pin is on the center of the cylinder bore. 18. Use suitable
thread protectors on the connecting rod bolts before inserting the piston and connecting rod
assembly into the cylinder block.
NOTE: Care must be taken not to nick the crank pin.
19. Using a suitable piston ring compressor tool, install the piston and connecting rod assembly
into the cylinder block.
NOTE:
Page 5889
6. Turn the ignition key to the "LOCK' position, disconnect the negative battery cable and tape the
terminal.
work.
Step 7: Clock Spring Installation
Align the mating marks of the clock spring by means of the following method, and then, install the
clock spring to the column switch.
Mating Mark Alignment Turn the clock spring clockwise fully, and then turn back it approx. 3 and
1/3 turns counterclockwise to align the mating marks.
CAUTION: If the clock spring's mating mark is not properly aligned, the steering wheel may not
rotate completely during a turn, or the flat cable within the clock spring may be severed, obstructing
normal operation of the SRS.
Air Bag Module Installation
Step 2: Air Bag Module Installation
Route the horn switch harnesses as shown in the illustration, and then install the air bag module
without clamping the harnesses.
1. After installing the clock spring, the steering wheel, the column covers and the air bag module,
check steering wheel for noise, binds or difficult
operation.
2. Reconnect the negative battery terminal. Turn the ignition key to the "ON" position. Does the
"SRS" warning light illuminate for about 7 seconds,
turn off and then remain off for at least 45 seconds? If yes, SRS system is functioning properly. If
no, consult SRS Warning Light Inspection.
Meter
Meter
Disassembly Steps
Disassembly
Reassembly

Page 4938
CAUTION: Do not remove the check valve from the vacuum hose. If the check valve is defective,
replace it together with the vacuum hose.
Page 4399

Page 5856
1997 Montero, Volume 1, page 52B-4
With Scan Tool
connector.
Page 5178
RELAY VIEW
Accessory Socket Relay G

Page 3307
Idle Speed/Throttle Actuator - Electronic: Oscilloscope Patterns and Waveforms
(1) Disconnect the stepper motor connector, and connect the special tool (test harness:
MB998463) in between. (2) Connect the analyzer special patterns pickup to the stepper motor-side
connector terminal (1) (red clip on the special tool), terminal (3) (green
clip), terminal (4) (black clip) and terminal (6) (yellow clip) respectively.
Connect the analyzer special patterns pickup to ECM terminals (4), (5), (17) and (18).
The wave pattern appears for an instant, but soon disappears.
Check that the standard wave pattern appears when the stepper motor is operating.
Point A: Presence or absence of induced voltage from the motor turning. (Refer to the abnormal
wave pattern.)
Point B: Height of coil back electromotive force.

Change

REVISION
the new rotors.

Page 2046
OPERATION
engine is cold.
Page 2668
Wire Color Codes
the marking color.

Page 4512
Differential: Service and Repair
DISASSEMBLY
ASSEMBLY
A. Center differential case installation. (1)
1. Pay attention to the positions of the dowel pins when reassembling, and make sure that the
match marks on the outside circumference are in
alignment.
Page 2461
OPERATION
ground.
Page 6823
Backup Lamp: Description and Operation
- When the ignition switch is turned to the ON position and the shift lever (or the selector lever) is
moved to the R position (or the park/neutral position switch (A/T) is switched to the R position), the
back-up light switch (M/T) is switched on and the back-up lights illuminate.
Page 719
Grounding Markings

Specifications
Operating Pressure

Page 552
OPERATION
Page 4843
shown.
Page 5261

Page 51

Refrigerant Oil: Capacity Specifications CAPACITY
CAPACITY
120 C.C. 4.10 Oz. (US)

Page 3546
Inspection
HARNESS INSPECTION
NOTE -
Page 4186
3. Check the tooth contact of the drive gear and drive pinion.
NOTE: Checking the tooth contact pattern is the way to confirm that the adjustments of the pinion
height and backlash have been done properly. Continue to adjust the pinion height and backlash
until the tooth contact pattern resembles the standard pattern. If the correct tooth contact pattern
cannot be obtained even after adjustments, the drive gear and the drive pinion must be worn
beyond the allowable limit. Replace the gear set.
REAR DIFFERENTIAL LOCK

Page 1906
reprogramming.

Page 6422
Power Switch Check
Operations Check

Page 3736
Page 5746
Hose/Line HVAC: Service and Repair
>A< SUCTION HOSE/RECEIVER INSTALLATION
When replacing the suction hose or the receiver with new ones, refill them with a specified amount
of compressor oil and then install each of them. Compressor oil: ND-OIL 8 Quantity:
Suction hose: 10 cubic cm (0.3 fl.oz.) Receiver: 10 cubic cm (0.3 fl.oz.)

NO.: TSB-95-16-003
MODEL: All Models
VEHICLES AFFECTED
All models
PROCEDURE
CAUTION:

Page 5534
the vehicle.
rear springs.
NOTE:
Page 5943
Teck Line.
Page 3073
Grounding Markings

Specifications
Hose/Line HVAC: Specifications
With suction hose replacement add refrigerant oil. ND-OIL 8 .............................................................
............................................................................................................................ 10 cubic cm (0.3 fl.
oz.)
Page 2040
Grounding Markings

Page 2249
on actual vehicles.
Wire Color Codes
Page 6592
on actual vehicles.
Wire Color Codes
Page 2082


Specifications
Thermostat: Specifications
Full Opening Temperature ...................................................................................................................
........................................................... 95° C (203° F) Valve Opening Temperature ...........................
................................................................................................................................................ 82° C
(180° F)
Page 3911
Page 3711
INSPECTION
Using Scan Tool
HARNESS INSPECTION
NOTE:
Page 1574
Intake Manifold: Specifications Service Specifications
Distortion Of Cylinder Head Contacting Surface:
Standard ..............................................................................................................................................
.......................... Less Than 0.15 mm (0.0059 inch) Limit ...................................................................
............................................................................................................................... 0.3 mm (0.012
inch)
Page 1104
Power Steering Fluid: Testing and Inspection
FLUID LEVEL CHECK
1. Park the vehicle on a flat, level surface, start the engine, and then turn the steering wheel
several times to raise the temperature of the fluid to
2. With the engine running, turn the wheel all the way to the left and right several times.
3. Check the fluid in the oil reservoir for foaming or milkiness. 4. Check the difference of the fluid
level when the engine is stopped, and while it is running. If the fluid level changes considerably, air
bleeding
should be done.
Page 4811
Wire Color Codes
the marking color.

Page 3591
Grounding Markings

Specifications
Firing Order .........................................................................................................................................

............................................................. 1-2-3-4-5-6.
Page 5570
- Operational steps after installation as follows: 1. Front wheel alignment inspection and
adjustment. 2. Bleed brake line.
Page 3169

Locations

Page 5473
statement as shown.
Page 3031
Page 5964

Page 6099
Page 1470
d. Tighten the fixing bolt.
Page 5278
Center Link: Service and Repair
STEERING LINKAGE
REMOVAL

Federal
OPERATION
Page 2458
on actual vehicles.
Wire Color Codes
Page 5348
on actual vehicles.
Wire Color Codes
Page 1994
connected.)
connector.
increased.
Page 5979
value.
new one.
Page 1441
Valve Seat: Service and Repair Seat Replacement
1. Cut the valve seat to be replaced from the inside to thin the wall thickness. Then, remove the
valve seat.
2. Rebore the valve seat hole in the cylinder head to a selected oversize valve seat diameter.
Intake Seat
0.3 O.S.: 34.30 - 34.33 mm (1.3504 - 1.3516 inch) 0.6 O.S.: 34.60 - 34.63 mm (1.3622 - 1.3634
inch)
Exhaust Seat
0.3 O.S.: 31.80 - 31.83 mm (1.2520 - 1.2531 inch) 0.6 O.S.: 32.10 - 32.13 mm (1.2638 - 1.2650
inch)
3. Before fitting the valve seat, either heat the cylinder head up to approximately 250° C (482° F) or
cool the valve seat in liquid nitrogen, to prevent
the cylinder head bore from galling.
4. Using a valve seat cutter, correct the valve seat to the specified width and angle.
Page 4295
Constant Velocity Joint Boot: Capacity Specifications
REPAIR KIT GREASE QUANTITY
Birfield Joint (B.J.) Assembly ...............................................................................................................

..................................................... 130 g (4.6 oz.) Double-Offset Joint (D.O.J.) Assembly
..................................................................................................................................................... 100
g (3.5 oz.)
Page 2271
Page 2164
OPERATION
high to low.
Locations

HARNESS INSPECTION
Page 4769
8. If a different result is obtained when checking, correct it by following the procedure in the
illustration.
HU (MOTOR) OPERATIONAL CHECK
Connect the battery and check that the sound of the hydraulic unit (motor) can be heard operating.
Caution: The battery power should not be applied for more than 1 second.
Page 2098


Page 1601

Page 3594
on actual vehicles.
Wire Color Codes
Page 1573
Intake Manifold: Specifications
Throttle Body Bolt 9.8-13 Nm
PAGE REFERENCE
Page 647
Grounding Markings

Page 137

Page 395
on actual vehicles.
Wire Color Codes
Page 7046
Horn Relay
Horn Relay - Check

Page 545

Locations
Number One Cylinder
Page 335
on actual vehicles.
Wire Color Codes
Page 5346

Page 6222
driver injury.
Page 6270


Page 2482


Page 35
CONTROL UNIT VIEW
Input Speed Sensor
INSPECTION
Specifications
At 20° C (68° F) ...................................................................................................................................

................................................... 36 - 46 ohms
Page 2304


Page 333

Page 104
Centralized Relay
Page 7063

Fluid - A/T: Capacity Specifications
Automatic Transmission Fluid Capacity
Capacity................................................................................................................................................
........................................................................ 8.9 Qt.
Specifications
Camshaft Gear/Sprocket: Specifications
Mounting Bolt .......................................................................................................................................

.............................................. 88 Nm (65 ft. lbs.)
Page 2931
Grounding Markings

Page 5093
Bolt ......................................................................................................................................................
...................................... 13 Nm (108 inch lbs.) Nut .............................................................................
................................................................................................................. 4 Nm (34.8 inch lbs.)
Page 637
(A4 - 76, B4 - 79)
(A3 - 34, B3 - 42)
- 92)

Page 6980

Specifications
...................................................................... 1.12 W
Page 6848
NOTE:
Specifications
Fluid Pump: Specifications
Body Clearance:
Standard Value
....................................................................................................................................................
0.07-0.15 mm (0.0028-0.0059 inch) Limit ............................................................................................
................................................................................................ 0.3 mm (0.012 inch)
Tip Clearance:
Standard Value
....................................................................................................................................................
0.11-0.14 mm (0.0043-0.0055 inch) Limit ............................................................................................
................................................................................................ 0.3 mm (0.012 inch)
Side Clearance:
Standard Value
....................................................................................................................................................
0.02-0.05 mm (0.0008-0.0020 inch) Limit ............................................................................................
................................................................................................ 0.3 mm (0.012 inch)
Body ....................................................................................................................................................
.................................... 38.18 mm (1.503 inch) Stator Shaft (Front) ....................................................
.............................................................................................................. 21.57 mm (0.849 inch) Stator
Shaft (Rear) .........................................................................................................................................
.......................... 27.07 mm (1.066 inch)
Oil Pump ..............................................................................................................................................

................................................. 22 Nm (16 ft. lbs.) Oil Pump Stator ....................................................
............................................................................................................................ 8 Nm (69.6 inch
lbs.)
Page 6839
Wheel Fastener Torque
Wheel Fastener: Specifications Wheel Fastener Torque
Wheel Nut ............................................................................................................................................

.......................... 98 - 118 Nm (72 - 87 ft. lbs.)
Page 5852
1997 Galant, Volume 1, page 52B-4

Page 2126
SENSOR VIEW

Page 315
installation.
REAR REPLACEMENT
Page 3236
Grounding Markings

Page 2875

Specifications
Cruise Control Vacuum Solenoid: Specifications
Solenoid Valve .....................................................................................................................................
............................................................ 50 - 60 Ohms
Page 5459
1. Front wheel alignment inspection and adjustment. 2. Bleed brake line.

Lower
REMOVAL
NOTE: Removal service points as follows: a. Lower ball joint and knuckle disconnection (5).
Page 2984
Grounding Markings

Page 2876


Page 708
Page 4216
3. Place dial gauge on unlocked pinion gear and measure differential gear backlash within the
standard value.
Standard value:
Conventional differential: 0.10-0.25 mm (0.004-0.01 inch) Rear differential lock: 0.15-0.20 mm

(0.005-0.008 inch)
4. When backlash exceeds the standard value, adjust with selected side gear spacer (LH). 5. Install
washers, pinion gears, pinion shaft holder and pinion shaft-A and B. Lock withe lock pin through
case B.
B. Backlash adjustment on differential gear case A side. (-)
Adjust backlash as follows:
1. Install side gear (RH) and 2 side gear spacers [1.0 mm (0.039 inch) thick]. Press differential case
A to differential case B. 2. Measure flange space (C) between differential case A and B with
thickness gage. 3. Calculate side gear spacer (RH) thickness (D) as follows: D = 2.0 mm (0.078
inch) - [C + 0.2 mm (0.008 inch)
4. Choose spacer with a thickness nearest D in 3 and adjust differential gear backlash on the right
side.
5. Match the match marks and assemble cases A and B. 6. Assure smooth rotation of inner shaft.
Power Window - Motor & Regulator Assembly Procedures
Power Window Motor: Technical Service Bulletins Power Window - Motor & Regulator Assembly
Procedures
NO. TSB-97-42A-003 DATE: February, 1997 MODEL: See Below
PURPOSE
In the past, the power window motor and regulator were supplied as a complete unit for
replacement parts. For listed models the motor and regulator are now available separately. The
affected service manuals do not include instructions for motor and regulator assembly or drum and
regulator wire assembly. Use the instructions in this bulletin along with those in the service manual
when replacing the power window motor and/or regulator.
AFFECTED VEHICLES 1992-97 Montero 1992-95 Expo/Expo LRV
AFFECTED MANUALS The following manuals do not include the procedures covered in this
bulletin for power window motor/regulator assembly and drum and regulator wire assembly.
1992-95 Montero Service Manual Volume 1 1996 Montero Service Manual Volume 1 1997 Montero
Service Manual Volume 1 1992-96 Expo/Expo LRV Service Manual Volume 1
PROCEDURE ^
POWER WINDOW MOTOR AND REGULATOR ASSEMBLY
CAUTION
Be careful when handling the power window motor. otherwise, the wire may come off the drum due
to the reaction force of the spring.
1. The new part comes with a tie-wrap to hold the assembly together during shipping. This tie must
be removed before proceeding. While holding the case and metallic cover by hand, cut off the
tie-wrap with side cutters or similar tool.
2. Remove the metallic cover.
Note:
If the wire has come off of the drum, restore the wire according to the DRUM AND REGULATOR
WIRE ASSEMBLY procedures elsewhere in this bulletin.
3. Using the guide and motor housing opening and drum housing guide tab as assembly reference
points, align the drive shaft of the power window
Page 1757

Page 1834
Wire Color Codes
the marking color.

Locations
CONTROL UNIT VIEW

Page 4051
Transmission Cooler: Service and Repair

REMOVAL
1. Remove under cover and under skid plate. 2. Drain automatic transmission fluid. 3. Follow
removal steps outlined in illustration.
INSPECTION
1. Check the hose and pipe for crack, damage and clogging. 2. Check for rusted or clogged
radiator oil cooler. 3. Check the fluid cooler fins for bends, damage or foreign materials.
INSTALLATION

Page 4206
Page 3653
OPERATION CHECK
pressure equalizes.

Page 3115
Grounding Markings

Application and ID
Constant Velocity Joint: Application and ID
GENERAL INFORMATION
Joint type:
Inner: Double-offset joint. Outer: Birfield joint.

Page 6491

Page 1826

SENSOR VIEW

Rocker Arm Assembly: Technical Service Bulletins Valve Lash Adjuster Noise - Troubleshooting
Procedures

PROCEDURES
Starion
shown.
PROCEDURES

checks:
NOTE: (1)
adjuster.
Page 377
INSPECTION
curve in the graph.
TESTING
replaced.
Page 6378
Page 5280
Standard value:
INSTALLATION
Page 2787
INSPECTION
Using Scan Tool
HARNESS INSPECTION
harness. (A2 - 92)
(A1 - 83)

Page 6835


Page 2798

Locations

Page 585
Grounding Markings

Page 3445
INSPECTION
Using Scan Tool
HARNESS INSPECTION
(A2 - 87)
- 92)
Page 6287
Paint: Locations
Page 2519
harness. (A3 - B1)
(A1 - Ground)
harness. (A2 - 89)

Ventilators (Air Outlet)
Air Duct: Service and Repair Ventilators (Air Outlet)

Page 3417
Throttle Body: Testing and Inspection
DASH POT
(1) Push the dash pot rod in lightly and confirm the resistance.
NOTE: 1. Resistance increases as the rod is pushed harder. 2. If the rod can be pushed in with no
resistance, either the diaphragm or check valve is faulty.
(2) Release finger and confirm that the rod returns to its original position quickly.
NOTE: If the rod returns slowly, the check valve is faulty.

Page 6080
Speaker: Service and Repair Rear Speaker
Rear Speaker - Removal And Installation
NOTE: * indicates that the speakers are installed on the right side also.
Removal
Installation

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Spark Plug - Fouling

Spark Plug: Customer Interest Spark Plug - Fouling

DATE: November, 1995

MODEL: All Models

SUBJECT: SPARK PLUG FOULING

1. Start the engine and warm to normal operating temperature.

2. Clean the spark plugs as follows:

Do not exceed the driving or engine rpm speeds listed below.

Use standard warranty procedures.

Using Scan Tool

Relay Box: Component Locations

How to Read Circuit Diagrams

Starter Relay: Testing and Inspection

Starter Relay - Chart

Transmission Position Switch/Sensor: Technical Service Bulletins A/T - Park/Neutral Position

NO.: TSB-98-23-012 DATE: August, 1998 MODEL See below

SUBJECT: PARK/NEUTRAL POSITION SWITCH ADJUSTMENT - SERVICE MANUAL REVISION

[TSB Revision TSB-98-23-012]

Air Bag(s) Arming and Disarming: Technician Safety Information

precautions and procedures.

2. Do not use any electrical test equipment on or near SRS components.

Never use an analog ohmmeter.

3. Never Attempt to Repair the Following Components

- Front Impact Sensors

- SRS Air Bag Control Unit (SRS-ECU)

- Air Bag Module

- Check dedicated fuse No. 5.

- Check the lighting switch. See: Testing and Inspection

- Check fusible link No. 13.

2. Either light does not illuminate.

- Check the bulb.

- Check the ground circuit.

Heated oxygen sensor connector: Disconnected

STEP 4. Check for continuity of the ground circuit. -

HEATED OXYGEN SENSOR CHECK

heated oxygen sensor side.

connector [approx. 12 Ohm at a temperature of 20°C (68°F)].

(3) It there is no continuity, replace the heated oxygen sensor.

g. Cam ring installation (4).

h. Vane installation (3).

Transmission Position Switch/Sensor: Technical Service Bulletins A/T - Park/Neutral Position

NO.: TSB-98-23-012 DATE: August, 1998 MODEL See below

SUBJECT: PARK/NEUTRAL POSITION SWITCH ADJUSTMENT - SERVICE MANUAL REVISION

[TSB Revision TSB-98-23-012]

How To Read Configuration Diagrams

NO.: TSB-97-11-002 DATE: February, 1997 MODEL: See Below

SUBJECT: NEW VALVE LASH ADJUSTER NOISE CHECKING AND TROUBLESHOOTING

1990-96 Truck 1989-90 Van/Wagon

SERVICE MANUAL REVISION

Lash Adjuster Noise Check

If an abnormal noise (chattering or clicking noise), suspected to be a malfunctioning lash adjuster,

SUBJECT: FOULED SPARK PLUGS

How To Read Configuration Diagrams

Brake Lamp: Electrical Diagrams

Stop Light (Part 1 Of 2)

Alternator Relay: Locations

Relay Location Overviews

Follow disassembly steps outlined in illustration.

Assembly in reverse order as Disassembly.

NOTE: Assembly service points as follows: